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Thirteen-Speed Transmission

1. 5 DESCHID ME T 5 6 Nine Speed Manual 6 Ten Speed Manual Transmissions ccccsseccecseececeeeecesaeeseeceeeceeseaueeeseuseessaeeeesaaeeess 6 Thirteen Speed Manual Transmissions 2 eroe eter orent inne annue nnn n ains 6 Design Level 1 Manual Transmissions 6 Design Level 2 Manual Transmissions cccccsscccsecceeeeceeeeseececeuecceeeseeeeseaeeseneeseeeens 8 daear Ue 9 i cielo ra TE 12 12 Installing Gasket Sealant 12 MAS OC CUIIG Used 15 19 Cleaning Ground or Polished Parts 19 Cleaning Rough Parts NO TE 19 Drying the Cleaned EM UEM UE 19 Preventing Corrosion or Rust on Cleaned 19 Section 2 Lubrication and 20 Transmission OM DS CHICA OWNS 20 Transmissions OI OOS RETE DT 20 Scheduled Maintenance 21 Checking and Adjusting the Oil Level 21 Checking the Condition of t
2. eere 137 Disassembling the 137 Assemong Me 139 Section 15 Overhauling the Main Countershafts 150 Disassembling the Main Countershaft E EET mm 150 Assembling the Main 152 Section 16 Overhauling the Auxiliary Case 155 Disassembling the Auxiliary Case Nine Speed and Ten Speed Transmissions 155 Assembling the Auxiliary Case Nine Speed and Ten Speed Transmissions 163 Disassembling the Auxiliary Case Thirteen Speed Transmissions 174 Assembling the Auxiliary Case Thirteen Speed Transmissions 182 Section 17 Main Countershaft End Play Adjustment 193 Checking and Adjusting the End Play of the Main Countershafts 193 Section 18 Auxiliary Countershaft End Play Adjustment 200 Checking and Adjusting the End Play of the Auxiliary Countershafts 200 Section 19 Troubleshooting 207 General Information 207 Troubleshooting Other Systems 208 TEDEDIGSHOO FHO LEIKE 209 Tro bleshooting VIDT
3. The standard position top cover and the ame 7 forward position top cover use different S ls HE housings The forward position hous JMA E ing uses a plate and a gasket installed over the detent balls and springs 1 Remove the top cover from the trans mission case as described in this section Make sure the top cover is in the NEUTRAL position Figure 8 3 Page 55 Section 8 Standard Pattern Overhauling the Top Cover Assembly Top Cover 2 On forward top covers remove the capscrews that fasten the spring cover plate if installed to the top cover Remove the plate and the gasket NOTE If a heavy duty detent spring is used the spring different color is in the bore on the slave valve side of the transmission 3 If installed remove the three detent springs and balls from the top of the housing Figure 8 4 Figure 8 4 BALL AND SPRING 4 cauTION Do not damage the machined surface of the case If the surface is damaged the case will leak 4 Put the top cover on the bench so that the forks are toward you or in a vise with brass protectors on the jaws 5 Remove the capscrews that fasten the large and the small oil scoops to the cover Figure 8 5 6 Cut and remove the lock wire on the fork sleeve and set screw assembly Figure 8 5 Page 56 Figure 8 5 7 Remove the set screws that fasten the shift fork and sleeve assembly to the shift shafts Figure 8
4. 1 gc ic gt 10008 ES T 9 Install the auxiliary cover on the output shaft and low gear assembly and the auxiliary countershafts See the fol lowing procedure d Install the outer bearing cone on the output shaft Make sure the letters on the cone are toward the top of the press a Put the output shaft and low gear assembly in a press Make sure the threads on the shaft are toward the top of the press Figure 16 30 e Install a sleeve on the outer bearing cone Press the cone on the shaft and into the cup in the bore of the cover Figure 16 32 b Put each auxiliary countershaft next to the output shaft Make sure the timing marks on each countershaft and the low gear are aligned Figure 16 30 Figure 16 30 Figure 16 32 TIMING MARKS ON AUXILIARY LOW GEARS TIMING MARKS ON COUNTERSHAFT LOW GEARS Page 167 Section 16 Nine Speed and Ten Speed Overhauling the Auxiliary Case Transmissions 10 Assemble the synchronizer assembly Figure 16 34 SPRING a Put the low synchronizer on the table so that the pins are toward you b Install the synchronizer collar over the pins on the low synchronizer Make sure the chamfered holes in the collar are over the pins and towards the low synchronizer Make sure the low synchronizer touches the collar Figure 16 33 Figure 16 33 COLLAR NOTE Put a towel under the low synchronizer to keep the assembl
5. pe ASSEMBLY HUB AND LO GEAR ASSEMBLY DESIGN LEVEL 1 DESIGN LEVEL 2 Page 174 13 Speed Section 16 Transmission Overhauling the Auxiliary Case Figure 16 51 AX WARNING To prevent serious eye injury always PISTONS wear safe eye protection when doing maintenance or service 1 Put the auxiliary cover in a holding fixture such as an axle repair stand 2 Remove the capscrews and washers that fasten the piston housing cover to the auxiliary cover Remove the cover and the gasket If necessary remove the fitting and the shuttle valve from the cover Figure 16 50 3 Remove the nuts and the washers that fasten the pistons to the shift shafts 5 Use a scraper to remove the gasket Discard the nut Figure 16 50 material from between the cover and the housing Figure 16 50 one 6 Inspect the O rings in the shaft bores of the piston housing If worn or dam aged replace the O rings Figure 16 52 A SHUTTLE VALVE Figure 16 52 O RINGS ISTON 1 HOUSING COVER 4 Remove the piston housing and the pistons as an assembly Inspect the O rings on the pistons Replace worn or damaged O rings Figure 16 51 Page 175 Section 16 13 Speed Overhauling the Auxiliary Case Transmission 7 Remove the mounting capscrews and washers from the output bearing re tainer Remove the retainer Use a scraper to remove the gasket material Hemove the speedometer gear from th
6. Figure 16 100 AX CAUTION Hold the seal only on the outer diameter Do not touch the inner diameter of the seal Touching contaminates the inner diameter of the seal and causes a leak between the shaft and the seal a Lubricate the outer diameter of the seal Put the oil seal in the cover Make sure the letters on the seal are installed away from the retainer O SEALANT PATTERN Page 190 13 Speed Section 16 Transmission Overhauling the Auxiliary Case 28 Install the mounting capscrews for the output bearing retainer Tighten the capscrews to 35 45 lb ft 47 61 Figure 16 101 29 Lubricate the O rings and the bores of the piston housing with the a silicone lubricant such as Dow Corning 111 Silicone Grease or equivalent Install the O rings in the grooves in the bores of the piston housing Figure 16 101 Figure 16 101 O RINGS GASKET PATTERN Figure 16 10 RANGE PISTON 30 Use a sealant dispenser and Loctite RTV Sealant 5699 Meritor Part Number 2297 A 7021 or equivalent to make a gasket pattern on the piston housing See Figure 16 102 for the gasket pattern See Installing the PISTON Sealant in Section 1 SPLITTER 31 Install piston housing on the auxiliary cover Make sure the shafts are in the correct bores Figure 16 103 33 Install the pistons on the shafts in the piston housings Make sure the pis tons are install on the correct shafts 32 Lub
7. In Vehicle Service Page 84 Nine Speed and Section 11 Ten Speed Removing and Installing Transmissions the Auxiliary Case Figure 11 1 7 UPPLY gt PORT d WARNING To prevent serious eye injury always wear safe eye protection when doing maintenance or service Removing the Auxiliary Case Nine Speed and Ten Speed Transmissions 1 If necessary remove the transmission and the output yoke as described in this section If the auxiliary case is removed with the transmission installed in the vehicle do the following Bon es If necessary remove the output yoke as described in this section b Remove the air from the air supply system c Puta large container under the transmission Remove both drain plugs Drain and discard the oll 2 Disconnect and mark the air lines Disconnect the BLACK tube from the LO range port On the piston housing OY cover disconnect the BLUE tube from Y the HI range port From the supply port of the filter and regulator Rey Qy assembly disconnect the RED tube Figure 11 1 4 On gear driven speedometers remove the driven gear from the NOTE output bearing retainer and the drive The auxiliary case must be in the LO gear from the output shaft range so that the case can be removed On electronic speedometers remove the sensor from the output bearing retainer and the rotor from the output shaft or disconnect the sensor at the connect
8. Assembling the Standard and the Forward Position X Bar Top Cover Assembly See Figure 8 32 and 8 33 NOTE The standard position X bar top cover assembly and the forward position X bar top cover assembly uses different covers The forward cover also uses a plate and a gasket installed over the detent balls and springs 1 Lubricate all the parts of the top cover with the oil that is used in the transmis sion 2 Do the following to the set screws that fasten the shift sleeves and or forks to the shift shafts and the capscrews for the oil scoops a Clean the threads of the fasten ers with Loctite amp Safety Solvent 755 Meritor part number 2297 P 6412 or equivalent Make sure all dirt is removed from the threads NOTE See the specifications of the sealant manufacturer for the cure time b Apply Loctite amp 242 Meritor part number 2297 V 5430 or equivalent to the threads of the fasteners 3 If disassembled install the plunger assembly in the low reverse fork as sembly See the following Figure 8 50 a Put the fork in a vise with brass jaws Page 72 a Cd Bar Top Cover b Install the ball and the spring in the bore next to the plunger c Install the plunger and the spring in the bore of the fork d Install the snap ring that holds the assembly in the fork PLUNGER AND SPRING Figure 8 50 4 Assemble and install the rocking lever assembly according to t
9. Does not operate Page 207 Section 19 Troubleshooting Troubleshooting Other Systems See the following chart to make sure the transmission is the cause of the problem SYSTEM CHECK FOR REPAIRS Engine Systems 1 Loose or missing fasteners 2 Engine idle speed out of specifications 3 Loose or damaged engine mounts 4 Out of balance fan 5 Damaged engine fan Clutch Systems 1 Loose or missing fasteners 2 Clutch out of adjustment 3 Clutch assembly out of balance 4 Worn or damaged pilot bearing Driveshaft 1 Systems Driveshaft system requires lubrication 2 Worn or damaged U joints and or yokes 3 Driveshaft out of balance 4 Center bearings not installed correctly or damaged 5 Driveline angles not correct Suspension 1 Systems Loose or missing fasteners 2 Damaged suspension components 3 Driveline touching frame 4 Loose or damaged cab mounts 5 Leaks in air suspension system 1 Replace missing fasteners Tighten to specified torque 2 Adjust idle speed to the specified range 3 Tighten the fasteners to the specified torque Replace damaged mounts 4 Replace fan 5 Repair or replace as required 1 Replace missing fasteners Tighten to specified torque 2 Adjust clutch 3 Replace clutch assembly 4 Replace pilot bearing 1 Lubricate driveshaft system 2 Replace U joints and or yokes 3 Balance driveshaft correctly or replace driveshaft
10. 03820431 1 1 J 0 0180 000 04320508 2 0 021 0 022 0 509 0 558 J 1 0 0280005 055906385 2 2 0 0260 0 7 0 636 0 685 1 1 e c __00280030 0 686 0 762 13 J 00310032 0 763 0 812 1 J 1 c __0 033 0 035 08190889 1 2 1 4 1 4 0 036 0 037 0 89009899 1 00880040 09401018 2 J 1 J 1 0041 0042 101710660 1 L4 c 1 __00430045 10671443 1 J 1 0 0460047 11441193 2 11 00480050 11941270 1 J 41 m 1 00510052 12713320 1 e 2 0 0523 0055 132194897 t p 1 0 056 0057 13981447 1 2 1 0 058060 14481524 1 1 p 1 0 061 0 062_ 1525 1574 13 J 1 1 0 063 0 065 157516581 2 J 1 J 1 0 066 0 067_ 165243701 1 2 1 1 J 1 0 0680070 17021778 2 J 1 J t1 1 1 Nh 0 071 0 072 1779 1828 gt J 1 f 1 Jo 1 0 073 0 075 1829940905 1 2 2 gt _ t bh 1 0 076 and above 1 906 and above 2 2 1 1 NIN Page 198 14 15 16 Section 17 Main Countershaft End Play Adjustment Repeat steps 1 5 and check the end play of the other main countershaft On D
11. 8 BOTTOM TWO CAPSCREWS c Use the transmission jack to re move the auxiliary case from the transmission case NOTE Sometimes the bearing cups for the auxiliary countershafts will remain in the bores in the main transmission case Hemove the cups Mark each cup for the correct location However if slip fit cups are installed the cups must be removed and replaced with press fit cups Nine Speed and Section 11 Ten Speed Removing and Installing Transmissions the Auxiliary Case Figure 11 9 Figure 11 10 AET SNAP RING 12 Use a slide hammer and a puller to the cups for the auxiliary counter remove the bearing cups for the auxil shafts Design Level 2 Transmis countershaft from the main case sions do not use snap rings in this Mark the cups The cups must be location Figure 11 10 installed in the original location 14 Use a scraper to remove the gasket Figure 11 9 material from the transmission case 13 On Design Level 1 Transmissions and the auxiliary case remove the snap rings in the bores for Page 89 Section 11 Removing and Installing the Auxiliary Case Installing the Auxiliary Case Nine Speed and Ten Speed Transmissions NOTE The auxiliary case must be in the LO range so that the case can be installed with the gears timed correctly 1 Use an air gun to apply air pressure to the LO range port in the piston housing to put the case in the LO range 2 On Design Le
12. Above 10 F 12 C Above 10 F 12 C Above 15 F 26 C Heavy Duty Engine Oil A P I CD CE SF or SG Current Designations Acceptable MIL 2104B C D or E Mineral Oil with Rust and Oxidation Inhibitor A P I GL 1 Above 10 F 12 Above 15 F 26 C 40 30 90 80 Use only the specified type of single weight oils Do not use multi viscosity and Extreme Pressure GL 5 gear oils Multi viscosity and EP gear oils may damage com ponents The use of multi viscosity or EP gear oils void the warranty Page 214 Section 20 Specifications Fastener Torque Locations Nine Speed and Ten Speed Transmissions TOP VIEW SIDE VIEW ht N de ax B l f FRONT VIEW FRONT VIEW WITHOUT CLUTCH HOUSING WITH CLUTCH HOUSING DESIGN LEVEL 2 Page 215 Section 20 Specifications Fastener Torque Locations Nine Speed and Ten Speed Transmissions Continued REAR VIEW REAR VIEW WITH AUXILIARY WITHOUT AUXILIARY COVER COVER DESIGN LEVEL 2 WITH ROUND RETAINER REAR VIEW TOP COVER WITHOUT AUXILIARY COVER STANDARD X BAR SHOWN DESIGN LEVEL 2 WITH TWO PIECE RETAINER Page 216 Section 20 Specifications Fastener Torque Locations Nine Speed and Ten Speed Transmissions Continued MAIN CASE MAIN CASE REVERSE IDLER GEAR OIL PUMP 28 SECTION A A 5 E SECTION B B Page 217 Section 20 Specifications Fastener Torque Chart Nine Speed and Ten Speed
13. If necessary put a small screw driver in the dot to move the washer Figure 14 8 15 Check the clearance between the third and the second gears or the overdrive and the third gears See the following procedure a Put two screwdrivers across from each other between the gears Figure 14 9 Lightly push on the screwdrivers to evenly spread the gears Make sure the gears are parallel to each other Figure 14 9 Figure 14 9 ni tiit WIL WIN 142 NOTE Do not push on the screwdrivers when the feeler gauges are installed C Put two small feeler gauges be tween the hubs Each feeler gauge must be opposite the other The clearance must be 0 006 0 012 inch 0 152 mm 0 304 mm Figure 14 10 Figure 14 10 FEELER GAUGES pe A UMN 8 CLEARANCE BETWEEN GEARS 0 006 0 012 INCH 90 152 0 304 MM d If the clearance is less than 0 006 inch 0 152 mm install a thinner selective thrust washer in the second or the third gear If the clearance is more than 0 012 inch 0 304 mm install a thicker selective thrust washer Three sizes of thrust washers are available For transmissions with serial num bers LB93021753 the sizes are 0 216 0 220 and 0 224 inch 5 50 5 60 and 5 70 mm For transmissions with serial num bers LB93021754 and above the sizes are 0 272 0 275 and 0 279 inch 6 90 7 00 and 7 10 mm Remove the
14. MAINDRIVE GEAR MARK ONE TOOTH ON EACH SIDE 180 APART TIMING MARKS D gt 2 4 2 On Design Level 1 Transmissions if required disassemble the input shaft See the following procedure Figure 12 41 a Lubricate all the parts with new oil that is used in the transmission b If removed install a new bushing in the end of the input shaft Use a hammer and the correct driver tool to install the bushing c Install the snap ring in the groove inside the main drive gear d Align the splines of the input shaft with the splines inside the main drive gear Install the main drive gear over the input shaft e Install the spacer on top of the gear Figure 12 41 RING BEARING a SPACER e MAIN DRIVE 85 GEAR d INPUT SHAFT f Use a press and a sleeve to install the bearing on the input shaft Support the bearing on the press so that the main drive gear is to ward the top of the press Press on the gear until the bearing touches the spacer Make sure the bearing rotates after the shaft is installed Figure 12 42 g Install the snap ring that fastens the bearing on the input shaft BUSHING Figure 12 42 Page 119 Section 12 Overhauling the Main Case 3 On Design Level 1 Transmissions install the input shaft See the follow ing a If installed remove the outer snap ring from the input bearing b Install the input shaft assembly t
15. Meritor part number 2297 P 6412 or equivalent Make sure all dirt is removed from the threads NOTE See the specifications of the sealant manufacturer for the cure time b Apply Loctite 242 Meritor part number 2297 V 2430 or equivalent to the threads of the set screws 2 Lubricate the bushings with a lithium 12 hydroxy stearate grease such as Multi Purpose grease Meritor specifi cation O 617 A or equivalent 3 If removed install the adjusting rod assembly in the housing Tighten the socket to 35 50 Ib ft 47 68 N m 4 If removed use a driver tool to install the bushings 5 Fill the area between the bushings with multi purpose grease Put the inner shift lever in position in the housing Install the shaft in the lever Install and tighten the set screw to 32 40 lb ft 44 54 Install the lockwire Install the boot over the shaft and on the housing Install new tie straps Put the outer shift lever on the shaft Make sure the outer shaft lever is aligned with the inner shaft lever Install and tighten the set screw to 32 40 Ib ft 44 54 N m Figure 6 2 Figure 6 2 LEVERS MUST BE ALIGNED Page 49 Section 7 Removing and Installing the Top Cover Assembly AX WARNING To prevent serious eye injury always wear safe eye protection when doing maintenance or service Removing the Top Cover Assembly NOTE Four different top cover assemblies are
16. Revised 12 98 2 50 9 10 and 13 Speed Transmissions Maintenance Manual 26A Service Notes This Maintenance Manual describes the correct service and repair procedures for the nine speed ten speed and thirteen speed Design Level One and Design Level Two manual transmissions You must follow your company safety procedures when you service or repair equipment Be sure you understand all the procedures and instructions before you begin work on the unit Meritor uses the following types of notes to give warning of possible safety problems and to give information that will prevent damage to equipment WARNING A waming indicates procedures that must be followed exactly Personal injury can occur if the procedure is not followed CAUTION A caution indicates procedures that must be followed exactly If the procedure is not followed damage to equipment or components can occur Personal injury can also occur in addition to damage or malfunctioning of equipment or components o TORQUE This symbol is used to indicate fasteners that must be tightened to a specific tourque value NOTE A note indicates an operation procedure or instruction that is important for correct service A note can also give information that will make service easier and quicker Some procedures require the use of special tools for safe and correct service Failure to use these special tools when required can cause injury to service personnel or damage to
17. splitter range of operation on thirteen speed transmis sions For more information see Mainte nance Manual Number 26B Nine Speed Manual Transmissions Air Shift Systems or Maintenance Manual 26D Thirteen Speed Transmissions Air Shift Systems Identification An identification plate is installed on the side of the transmission Use the informa tion on the identification plate when order ing parts Figure 1 2 See Figure 1 2 for an explanation of the model identification number and the identi fication plate Nine Speed Manual Transmissions The transmission is identified by the num ber 9 in the Speed portion of the model number Figure 1 2 The transmission uses nine forward gears five gears in the LO range and four gears in the HI range and two reverse gears The transmission may be either a Design Level 1 or a Design Level 2 See the explanation in this section Page 6 Ten Speed Manual Transmissions The transmission is identified by the num ber 10 in the Speed portion of the model number Figure 1 2 The transmission uses ten forward gears five gears in the LO range and five gears in the range and two reverse gears The transmission is a Design Level 2 See the explanation in this section Thirteen Speed Manual Transmissions The transmission is identified by the num ber 13 in the Speed portion of the model number Figure 1 2 The transmission uses thirteen
18. ton If worn or damaged remove and 3 Remove and discard the gasket be replace the O ring Figure 16 4 tween the range cylinder cover and the range cylinder housing Inspect the small O ring in the inner diameter of the piston bore If worn or Figure 16 3 P damaged remove and replace the O 4 Remove the nut from the piston in the ring Figure 16 4 range cylinder housing Figure 16 3 ge ey diio Inspect the piston especially the outer diameter for wear and damage f worn or damaged replace the piston and the housing as an assembly Page 156 Nine Speed and Ten Speed Section 16 Transmissions Overhauling the Auxiliary Case Figure 16 4 PISTON NOTE An O ring is used between the range cylinder housing and the auxiliary cover on Design Level 1 Nine Speed Trans missions Replace with gasket sealant during assembly 6 Remove the range cylinder housing from the cover Inspect the O ring in the bore for the shift shaft Replace if damaged lf used remove and re place the O ring between the housing and the auxiliary case with sealant with sealant during assembly Figure 16 5 Inspect the range cylinder housing especially the bore for wear and dam age If worn or damaged replace the piston and the housing as an assembly 7 Remove the mounting capscrews and washers from the output bearing re tainer to the auxiliary cover Remove the retainer Use a scraper to remove the sealant material fr
19. Check air bag height Correct as necessary CONDITION CAUSE REPAR Vibration In Fasteners do not remain tight 1 Tighten fasteners If fasteners do not Vehicle Repair remain tight replace fasteners or housing Vibration Damaged bearings 1 Replace bearings Remove and Broken or loose synchronizer 2 Replace synchronizer Disassemble pins Transmission NOTES Ifthe transmission does not shift correctly into the selected range broken or loose synchronizer pins are the result of the vibration condition Page 209 Section 19 Troubleshooting Troubleshooting Noises For all noise conditions check the following before disassembling the transmission Check that the oil level is even with the bottom of the fill plug hole 2 Make sure the correct oil is used 3 Make sure the driveline angles of the transmission are correct 4 Make sure the transmission is correctly installed 5 Remove the drain plug Check for any metal shavings gasket material or any other material in the oil In some noise conditions there are additional repairs to perform These repairs will be explained in the following charts See the following charts to troubleshoot the clutch CONDITION CAUSE REPAIR Growling 1 Worn or damaged gears 1 Replace gears Humming or 2 Worn bearings Humming only 2 Replace bearings Grinding 3 End play out of specifications 3 Check and adjust end play Hissing 1 Damaged bear
20. Color or hose diameter may vary by vehicle manufacturer 2 f 1 4 inch air lines and fittings are used replace the lines and fittings with 5 16 inch air lines and fittings Page 226 Section 20 Specifications Air Line Locations Thirteen Speed Transmissions P i a a LI z LL E poss E i M FILTER AND REGULATIOR ASSEMBLY PISTON HOUSING er es S Q Page 227 Section 20 Specifications Air Tube Identification C hart Thirteen Speed Transmissions Description Pilot Fitting on Selector 5 32 inch SAE J 844 Valve 1A to Pilot Fitting or A on Slave Valve 1B 1 8 inch Pilot Supply Fitting on Selector 5 32 inch SAEJ 844 Valve 2A to Pilot Supply Fitting or A on Slave Valve 2B 1 8 inch Exhaust Fitting on Selector 5 32 inch SAE J 844 Valve Or 1 8 inch Splitter Fitting on Selector 5 32 inch SAE J 844 Valve 4A to Splitter Fitting or A on Piston Housing Cover 4B 1 8 inch Supply Fitting on Filter 1 4 inch SAE 844 and Regulator 5A to Supply A Fitting on Slave Valve 5B LO Range Port on Slave 1 4 inch SAE J 844 Valve 6A to LO Range Port on Piston Housing 6B HI Range Port on Slave 1 4 inch SAE J 844 Valve 7A to HI Range Port A on Piston Housing Cover 7B Seethe specifications of the manufacturer of the vehicle for the color of the tube Page 228 Section 20 Specifications Hold
21. Figure 11 16 Figure 11 16 10 Remove the lifting bracket s and the lifting device from the auxiliary case 11 Install the auxiliary case against the transmission case If necessary use a uu rubber or plastic mallet to push the 8 Connect a lifting device to the lifting auxiliary case against the main case bracket s Figure 11 18 12 Install the mounting capscrews and washers for the auxiliary case Tighten the capscrews to 35 45 Ib ft 47 61 N m Figure 11 18 o Page 92 Nine Speed and Section 11 Ten Speed Removing and Installing Transmissions the Auxiliary Case Figure 11 18 Figure 11 19 LO RANGE PORT SUPPLY ZZ PORT P 2 ps E E a SN RANGE AZO e IJ 6 PORT Y 6 sett BEC MAEN CNN a BeLIvEAy oO PORT the top of the fittings automatically lock 13 Check and adjust the end play of the air lines in position each auxiliary countershaft Do the procedure described in Section 18 15 Connect the BLUE air line to the HI Auxiliary Countershaft End Play range port of the piston housing Con Adjustment When the correct end nect the BLACK air line to the LO play of 0 002 0 006 inch range port of the piston housing Con 0 050 0 152 mm is obtained go to nect the RED air line to the supply port step 14 of this procedure of the filter and regulator 14 If removed install the filter and assemDy Figure 11 139 regulator assembly See the 16
22. Inspect transmission input bearing retainer surface for excessive wear which can affect the clutch adjustment Figure 4 3 Figure 4 2 lt TRANSMISSION PULL TRANSMISSION STRAIGHT OUT ve INPUT SHAFT MAKE SURE TRANSMISSION IS NEVER SUPPORTED BY INPUT SHAFT Page 35 Section 4 Removing and Installing the Transmission Installing the Transmission see the recommended procedure from the manufacturer of the vehicle to install the transmission The following is a general procedure to install the transmission 1 Inspect the clutch housing for wear and damage Replace worn and damaged housings 2 Inspect the cross shaft bores in the housing Make sure plugs are in the bores that are not used If the bores are not plugged dirt and contaminants go into the clutch housing and damage the clutch Figure 4 4 Figure 4 4 is MAKE SURE THE UNUSED BORES ARE PLUGGED 3 Make sure an inspection cover is installed on the bottom of the clutch housing If an inspection cover is not used dirt and contaminants go into the clutch housing and damage the clutch Figure 4 5 Page 36 Figure 4 5 24 ig du hi NS R PF gt uu aS P p AT W Me G ly INSPECTION COVER 4 Inspect the input bearing retainer on the transmission Check the area where the clutch brake touches the retainer Replace worn or damaged retainers 5 Measure the distance from the
23. Install a new nut and the washer that 11 16 N m Figure 16 98 TS fasten the LO gear to the output shaft Tighten the nut to 220 260 lb ft Figure 16 98 299 352 N m Figure 16 97 o Figure 16 97 099 SS uL SHOULDER BOLT ASSEMBLY Page 189 Section 16 13 Speed Overhauling the Auxiliary Case Transmission 23 Move the cover in the fixture so that CAUTION the outside of the cover is toward you Use the correct tool to install the oil seal If the correct tool is not used the 24 If removed use the correct tool to seal will leak install a new bushing for the speedometer gear inside the output b Use seal driver tool 3256 Z 1014 bearing retainer Kent Moore Tool Number J 39161 to drive the seal into the cover he seal is correctly in stalled when the flange of the seal touches touches the retainer Figure 16 99 ud c ica 26 Use a sealant dispenser and Loctite RTV Sealant 5699 Meritor Part Number 2297 A 7021 or equivalent to make a 1 8 inch 2 mm gasket pattern on the cover for the output bearing retainer See Figure 16 100 for the gasket pattern See Installing the Sealant in Section 1 25 If removed install a new oil seal in the output bearing retainer See the following procedure Figure 16 99 2 Install the output bearing retainer on the auxiliary cover Make sure the oil passage in the retainer is aligned over the oil hole in the cover Figure 16 100
24. On Design Level 1 Transmissions discard the selective snap ring that is used to fasten the cup in the bore Install a spacer washer to adjust the end play 3 Remove the capscrews and the wash ers that fasten the Holding Cover Plates and or lift brackets on the coun tershaft and cover Remove the cover tool AX CAUTION Use spacer washer Part Number 1229 N 4538 with blue color to check the end play of the auxiliary countershaft If the wrong spacer washer is used the end play reading will not be correct 4 Install the thinnest spacer washer Meritor Part Number 1229 N 4538 with blue color in the bore on top of the cup Make sure the tab of the washer is aligned with the slot in the case Figure 18 1 Page 200 SPACER WASHER 1229 N 4538 Figure 18 1 5 Make sure the bearing cup and the spacer washer are in the correct posi tion See the following procedure Figure 18 2 Figure 18 2 a Install the cover for auxiliary coun tershaft b Install the capscrews and washers that fasten the cover to the auxiliary case Section 18 Auxiliary Countershaft End Play Adjustment c Alternately and evenly tighten the capscrews until the countershaft cover touches surface of the auxil lary cover DO NOT TIGHTEN MORE THAN 35 LB FT 47 N m d Remove the capscrews the wash ers and the countershaft cover NOTE Two designs of countershafts are used a single hole design and a two hole design
25. Puta sleeve or installation tool on the top of the outer cup Press both cups into the bore The cups are correctly installed when the flange on the outer cup touches the shoulder in the bore of the cover Figure 16 80 Page 183 Section 16 13 Speed Overhauling the Auxiliary Case Transmission Figure 16 80 Figure 16 81 Y la 111101 8 Install the auxiliary cover on the output shaft and OD gear assembly See the following procedure Figure 16 81 9 Put the gear and cover assembly ona bench Make sure the inside of the cover is toward you a Put the output shaft and OD gear assembly in a press Put a support under the gear Make sure the large threads on the shaft are toward the top of the press 10 Use paint to put timing marks on two teeth of each countershaft OD gear Make sure the mark is aligned with the dot on the counter shaft Figure 16 82 b Put the auxiliary cover on the output shaft assembly Rotate the cover to make sure the output shaft inner bearing cone is installed in the cup c Install the spacer on the top of the inner bearing cone of the output shaft d Install the outer bearing cone on the output shaft Make sure the letters on the cone are toward the top of the press TIMING e Install a sleeve on the outer bearing cone Press the cone on the shaft and into the cup in the bore of the cover 11 If necessary assemble the splitter fork and shaft assembly Figur
26. Remove the boot from the housing and the shift lever 4 Put the assembly in a vise with brass jaws Make sure the inside of the housing is toward you 6 Lift on the lower lever to remove the lever Remove the spring and the spacer from the lower lever 5 Remove the spiral snap ring that fastens the spring the spacer and the lower lever in the housing 7 Inspect all parts See Repairing or Replacing the Parts in Section 1 Page 46 Section 5 Overhauling the Shift Lever and Tower Assembly Assembling the Cast Iron Shift Lever and Tower Assembly See Figure 5 13 1 Put the housing in a vise with brass jaws Make sure the outside of the housing is toward you 2 Install the lower lever in the housing Make sure the slots on the ball of the lever are aligned with the pins in the housing Install the spacer over the lower lever Install the assembly in the housing Install the spring over the lower lever in the housing Install the spiral snap ring over the lower lever in the housing Make sure the snap ring is completely installed in the groove in the housing Install the boot on the housing Make sure the lip on the boot is installed in the groove in the housing Install new cable ties that fasten the boot to the housing If removed connect the upper lever to the lower lever See the following Figure 5 14 a Install the upper lever of the lower lever Make sure t
27. Transmissions Torque Range Description Lb Ft N m acea Capscrew Q Housing ir F itti ome 9 PTO Cover to Case Capscrew 8 Hole 7 16 14 UNC x 3 4 35 45 Drain and Fill Plugs to Main Case 1 1 16 12 UN 35 50 Clutch Housing to Main Case Nut 5 8 18 UNF 150 190 12 Clutch Housing to Main Case 1 2 13 UNC x 1 1 2 65 85 Capscrew 1 2 13 UNC x 3 1 2 65 85 13 Input Bearing Retainer to Main Case 3 8 16 UNC x 1 1 4 25 35 Capscrew 14 Front Cup Retainer to Main Case 120 140 Allen head Capscrew in Ibs 15 Countershaft Cover to Auxiliary Case 3 8 16 UNC x 1 29 35 Capscrew Air Filter Regulator End Air Filter Regulator to Auxiliary Case 1 4 20UNC x 2 Capscrew Range Cylinder Cover to Auxiliary Case 3 8 16 UNC x 2 3 4 35 45 Capscrew Auxiliary Cover to Main Case Capscrew 3 8 16 UNC x 1 1 2 35 45 Output Bearing Retainer to Main Case 3 8 16 UNC x 3 35 45 Capscrew Q Yoke to Output Shaft Nut G 2 16 UN 450 500 PTO Cover to Case Capscrew 6 Hole 3 8 16 UNC x 3 4 35 45 Auxiliary Drive Gear to Main Case 3 8 16 x 1 35 45 Capscrew Q Main Case Capscrew Rocking Lever Assembly Pin guide to Top Cover Housing Nut Capscrew Shift Fork to Shift Rail Set Screw 7 16 20 UNF 35 45 Reverse Idler Gear to Shaft Nut 5 8 18 UNF 75 100 Oil Pump to Main Case Capscrew 1 4 20 UNC x 1 1 2 7 10 See NOTES on the following page Page 218 47 67 34 47 47 67 21 27
28. cups for the main countershaft in the main case and for the auxiliary countershafts in the auxiliary case and the main case Selective snap rings are used to adjust the end play in the main case and the auxiliary case Design Level 2 Manual Transmissions Design Level 2 Nine Speed Ten speed and Thirteen Speed Manual Transmissions apply to all transmissions with serial num bers LB93002000 and above Page 8 The transmission is identified by the number 2 in the Design Level portion of the model number Figure 1 2 Retainer plates are used to retain the bearing cups for the main countershaft in the main case The bearing cover and the selective washer are used to retain the cups for the auxiliary countershaft in the auxiliary case selective shims are used to adjust the end play in the main case Selective washers are used to adjust the end play in the auxiliary case Gear Timing If the timing marks on the gears are not aligned in the main case or in the auxiliary case the transmission will not operate The timing marks must be correctly aligned when the transmission is serviced The timing marks will not go out of align ment during normal vehicle operation unless the gear teeth are damaged Timing Marks in Auxiliary Case NOTE To make sure the timing marks are in the correct locations count the number of gear teeth divide the total teeth number by 2 and put the mark in the correct location
29. fasten the shift sleeves and or forks to the shift shafts and the capscrews for the oil scoops a Clean the threads of the fasten ers with Loctite Safety Solvent 755 Meritor part number 2297 P 6412 or equivalent Make sure all dirt is removed from the threads NOTE See the specifications of the sealant manufacturer for the cure time b Apply Loctite 242 Meritor part number 2297 V 5430 or equiva lent to the threads of the fasteners 3 Install the top cover in a vise with brass jaws Make sure the low reverse bore holes are toward the bottom of the vise 4 Install the short pin in the bore for the neutral safety switch Install the switch or plug and tighten to 35 50 Ib ft 48 67 N m Figure 8 18 o Page 60 NOTE On standard position top covers one or two reverse switches may be used On forward position top covers one re verse switch is used 5 Install the breather vent in the top cover Tighten to 15 20 lb ft 21 27 N m Figure 8 18 6 Install the larger pin s in the bore s for the reverse switch Install the switches or plugs and tighten to 35 50 lb ft 48 67 N m Figure 8 18 Figure 8 18 LARGE PINS REVERSE SWITCH SHORT PIN NEUTRAL SAFETY SWITCH If disassembled install the plunger assembly in the low reverse shift 7fork See the following Figure 8 19 a Put the fork in a vise with brass jaws b Install the spring and the ba
30. side of the reverse idler gear Figure 12 75 111 d Put the reverse idler gear in posi tion in the top of the case 28 C Le EI C qu i S Ed jmn I il Yn From the auxiliary cover side of the transmission case install the shaft through the reverse idler gear REVERSE assembly GEAR f Install the nut and the washer on the upper reverse idler gear assem bly Hold the end of the shaft with dr Tiahten th i 15 Install a new snap ring that fastens the 75 100 lb ft 100 135 m nut to reverse gear on the mainshaft Make Figure 12 76 o sure the snap ring is completely in stalled in the groove Figure 12 78 1 i ni 2 4 LL iM pa LC ATT T 0 got 14 Move the reverse gear to the rear 16 Install the thrust washer on the main the mainshaft Remove the auxiliary shaft Figure 12 79 drive gear Figure 12 77 17 Install the auxiliary drive gear assem bly on the mainshaft and in the rear of the case See the following Page 132 Section 12 Overhauling the Main Case Figure 12 79 THRUST WASHER Figure 12 80 C Qf Saas 6 wea L EE zw LIT 1 i Round Retainer Figure 12 80 a Install the retainer the bearing and gear ass
31. 1 Figure 14 2 Assembling the Mainshaft See Figure 14 1 NOTE See Figure 14 1 to identify the compo nents of the mainshaft assembly for the transmission models CAUTION Use the correct snap ring in the gears or the transmissions will not operate correctly Transmissions with serial numbers LB93021753 and below use part number 1229 X 4418 Transmis sions with serial numbers LB93021754 and above use part number 1229 W 4625 1 If removed install the snap rings in the gears Figure 14 2 Section 14 Overhauling the Mainshaft WARNING When using a hammer and a steel drift wear safe eye protection and make sure the tools are in safe condition Do not use tools that are worn or damaged mushroomed If the tools are not in safe condition pieces can break and cause serious personal injury 2 If removed use a hammer and a steel drift to install a new roll pin Figure 14 3 Figure 14 3 3 Lubricate all the parts of the mainshaft with the same oil used in the transmission 4 Install the mainshaft in a vise with brass jaws Make sure the slot for the key is toward you Page 139 Section 14 Overhauling the Mainshaft CAUTION Use the correct selective washer Do not mix washers or the transmission Will not operate correctly 5 Choose the correct selective thrust washer for the third or overdrive gear See the following e Ifthe selective washers are not repla
32. 1 3 If a round retainer is used for the 2 Remove and discard the snap ring that auxiliary drive gear clean the puller fastens the auxiliary drive gear to the holes and install a 3 8 16 x 1 00 mainshaft Figure 12 1 capscrew in the three puller holes in the bearing retainer of the auxiliary drive gear Evenly tighten the three Figure 12 1 capscrews to remove the auxiliary drive gear from the mainshaft necessary tap on the mainshaft with a rubber or plastic mallet to separate the gear from the mainshaft Remove the round retainer Figure 12 3 Figure 12 3 PULLER SCREWS SNAP RING If a two piece retainer is used for the auxiliary drive gear use pry bars to separate the auxiliary drive gear from the mainshaft Remove the gear Remove and discard the O rings from the gear Remove the two piece retainer Figure 12 2 Page 104 Section 12 Overhauling the Main Case NOTE Figure 12 5 THRUST WASHER The ball bearing assembly for the auxil iary drive gear will sometimes come out when the auxiliary drive gear is re moved If necessary pull on the as sembly to separate the gear from the bearing 4 Put a pry bar under the snap ring on the ball bearing assembly for the auxiliary drive gear Remove the bearing Figure 12 4 SNAP RING 5 Remove the auxiliary drive gear thrust washer from the mainshaft Figure 12 5 6 Remove the snap ring from the reverse Figure 12 7 REVERSE LO
33. 1229 E 4217 0 017 0 021 0 407 0 533 0 083 2 12 1229 F 4218 Blue 0 022 0 026 0 534 0 660 0 088 2 25 1229 G 4219 Yellow there 0 038 0 042 0 940 1 067 70 104 264 _ Blue White 0 043 0 047 1 068 1 194 BRA 1229 L 4224 Orange White Page 195 Section 17 Main Countershaft End Play Adjustment Figure 17 7 Figure 17 8 COUNTERSHAFT CAPSCREW Repeat steps 1 5 to make sure the end 10 On Design Level 2 Transmissions if play is correct When the end play is the reading is 0 007 0 011 inch correct go to step 14 0 177 0 279 mm see the following 9 On Design Level 2 Transmissions if a Remove the Allen head capscrews the reading is less than 0 002 inch and remove the retainer 0 050 mm or there is no reading move the cup 0 125 inch 3 mm to b Remove the 0 005 inch 0 127 mm ward the outer surface of the case shim Meritor part number See the following procedure 2803 R 2826 a Remove the Allen head capscrews c Install the retainer Instal the Allen and remove the retainer head capscrews Alternately and evenly tighten the capscrews to b Use a yoke bar puller bridge 120 140 Ib in 14 16 N m T washer and a long 5 16 inch x 18 capscrew to move the cup d Check the end play as described in Figure 17 8 steps 1 5 of this procedure c After the cup is moved go to step 11 On Design Level 2 Transmissions if 13 t
34. 21 27 10 12 47 60 34 47 47 61 47 67 204 257 89 115 89 115 34 47 14 15 34 47 47 61 2 3 2 8 10 12 47 61 47 61 610 677 47 61 47 61 34 47 47 61 13 17 47 61 101 135 10 13 Section 20 Specifications Fastener Torque Chart Nine Speed and Ten Speed Transmissions Chart Continued tem pescrnton tek Rm Transmission ace Capscrew Ship Shoulder Bolt Piston to Shift Shaft Nut 7 16 20 UNF 35 50 48 67 33 Remote Control Housing to Top Cover 35 45 47 61 Capscrew Remote Control Housing Adjusting Rod 1 2 13UNC 35 50 47 67 Jam Nut Set Screw to Linkage Nut to Linkage Nut to Linkage Nut messes ee Set Screw NOTES fasteners with threads 1 4 inch 7mm or smaller put Loctite 222 Meritor Part Number 2297 B 6112 or equivalent on the threads On fasteners with threads greater than 1 4 inch 7mm threads or Smaller put Loctite 242 Meritor Part Number 2297 V 2430 or equivalent on the threads Put a new application of Loctite or equivalent if any of the following occur a Anew fastener is installed b The sealant is removed from the threads C The fastener is removed the third time from the transmission Requires Loctite amp 242 Meritor Part Number 2297 V 2430 or equivalent and lockwire After the capscrews are tightened to the specified torque do not loosen or tighten the capscrews If the cap screws are loosened o
35. 3 4 shift fork shaft in the top bore at the front of the housing Figure 8 59 b Put the 3 4 shift fork in the housing Make sure the slot on the fork is aligned with the rocking lever assembly Make sure the bore of the fork and sleeve assembly is aligned with the bore in the hous ing Figure 8 59 X Bar Top Cover i 3 4 SHIFT FORK 3 4 SHIFT FORK SHAFT c Push the shift shaft through the 3 4 fork 4 After the set screws with the Loctite sealant see step 2 are tightened to the specified torque do not loosen or tighten If loosened or tightened the set screws must be removed cleaned and new sealant applied or the set screws may loosen during operation d Install the set screw with the Loc tite Sealant see step 2 that fastens the 3 4 fork to the shaft Tighten the set screw to 35 45 Ib ft 47 54 N m e Install the lock wire in the holes in the set screws and the fork 13 If removed install the large and small oil scoops on the housing Install and tighten the capscrews with the Loctite sealant see step 2 to 10 13 lb ft 14 17 N m Figure 8 60 4 Section 8 Overhauling the Top Cover Assembly Figure 8 60 LARGE OIL S SMALL OIL SCOOP NOTE On standard position top covers assem blies one or two reverse switches may be used On forward position top cov ers one reverse switch is used 14 Install the larger pin s in the b
36. 30 Figure 12 31 Page 115 Section 12 Overhauling the Main Case Removing the Magnets 1 Remove the auxiliary drive gear the mainshaft the input shaft and the countershafts as described in this section 2 Remove the magnets from the bottom of the case Figure 12 32 Figure 12 32 MAGNETS Page 116 Removing the PTO Covers 1 Drain the lubricant from the transmis sion See Draining and Replacing the Transmission Oil in Section 2 Lubrication and Maintenance 2 Remove the capscrews that fasten the PTO covers to the side and the bottom of the case Remove the covers Figure 12 33 3 Use a scraper to remove the sealant material from the PTO covers and the case Figure 12 33 COVERS Section 12 Overhauling the Main Case Figure 12 34 PTO COVERS TO TRANSMISSION CASE GASKET PATTERN Installing the PTO Covers 1 Use a sealant dispenser and Loctite RTV Sealant 5699 Meritor Part Number 2297 A 7021 or equivalent to put a sealant pattern for the PTO covers on the case Put a gasket sealant on the case See Installing the Sealant in Section 1 General Information See Figure 12 34 for the pattern for the bottom cover See Figure 12 35 for the pattern for the side cover Install the 8 hole PTO cover on the bottom of thecase Install the mount ing capscrews and washers Tighten the capscrews to 35 45 lb ft PUT THE PATTERN ON THE
37. 4 Install center bearings correctly or replace 5 Adjust driveline angles to manufacturer s specifications 1 Replace missing fasteners Tighten to specified torque 2 Repair or replace damaged suspension components 3 Adjust so that driveline does not touch frame 4 Tighten loose fasteners to the specified torque Replace damaged mounts 5 Repair leaks Check all valves for correct operation Power Take Off 1 PTO does not engage or 1 Repair or replace PTO assembly PTO Systems disengage correctly Wheels and Tires 1 Wheels and tires out of balance 2 lires do not match on each side of the vehicle Low lubricant level 2 Linkage out of adjustment 3 Linkage binding or unable to move Remote Shift 1 Systems Page 208 1 Balance or replace wheels and and tires 2 Install tires of the same size on all sides of the vehicle 1 Fill to specified level 2 Adjust linkage 3 Lubricate repair or replace linkage Section 19 Troubleshooting Troubleshooting Leaks Before troubleshooting a leak condition make sure of the following 1 Clean the outside of the transmission to remove all dirt 2 Operate the vehicle to make sure the leak is coming from the transmission 3 Verify that the fluid is transmission oil 4 The transmission housings are not cracked or broken CONDITION CAUSE REPAIR Leaks In Vehicle 1 Missing fasteners Replace missing fasteners Repair Tighten to specif
38. 41 15 mm 1 0 INCH 25 4 mm 151 MM 0 375 INCH DIAMETER 9 53 mm 2 25 INCH 57 15 MM 0 25 INCH 6 35 MM Nine Speed and Section 11 Ten Speed Removing and Installing Transmissions the Auxiliary Case d On Design Level 2 Transmis 8 Remove the mounting capscrews and sions only install two lifting brack washers from the auxiliary case ets and two capscrews on each auxiliary countershaft Install the brackets opposite each other as shown in Figure 11 5 9 Clean the puller holes in the auxiliary case Install a 3 8 16 x 1 1 2 UNC capscrew into the three puller holes Evenly tighten each capscrew to sepa rate the auxiliary case from the trans mission case Figure 11 6 Figure 11 5 Figure 11 6 LIFTING BRACKET HOLDING COVER PLATE 3305 W 1141 g 54 PULLER HOLES AX CAUTION If required remove the dowel pins from the case side Do not hit the tapered ends of the dowel pins If the ends of the dowel pins are damaged the auxil lary case will be difficult to separate from the main case Also the lower dowel pin cannot be removed from the yoke side of the auxiliary case d WARNING When using a hammer and a steel drift wear safe eye protection and make sure the tools are in safe condition Do not use tools that are worn or damaged mushroomed If the tools are not in safe condition pieces can break and 7 Clean the dowels pins Remove paint cause serious
39. Inspect the bore for the seal in the output bearing retainer and the seal journal on the output yoke for wear or damage Replace the retainer if worn or damaged 2 Lubricate the outer surface of the output bearing retainer where the seal is installed with the oil that is used in the transmission Ay caution Hold the seal only on the outer diame ter Do not touch the inner diameter of the seal Touching contaminates the inner diameter of the seal and causes a Section 3 In Vehicle Service 5 Clean the seal driver tool Put the oil seal on the seal driver tool so that the spring is away from the tool Make sure the seal is flat against the surface of the tool Figure 3 13 leak between the shaft and the seal Figure 3 13 3 Install the oil seal in the output bearing SPRING retainer caution Use only the specified seal driver tool If a different driver tool is used the seal will not be installed at the correct depth and will leak 4 Use seal driver tool Meritor Part Num ber 3256 Z 1014 or Kent Moore Part Number J 39161 to install the seal Clean and inspect the tool Replace the tool if the area that touches the seal is worn or damaged Figure 3 12 6 Drive the seal into the retainer until the flange on the tool touches the retainer Make sure there are no gaps between the tool and the retainer Figure 3 12 2 7 gt S 4 cauTION Use a cleaning solvent to clean the yoke Do
40. Install the capscrews and washers for the retainer Tighten the capscrews to 65 85 Ib ft 89 115 N m Figure 9 14 Install the top cover and the transmis sion See the procedure in this section Operate the vehicle Check for correct operation Page 82 Figure 9 13 SEALANT PATTERN OIL SLOT Figure 9 14 yi d Section 10 Removing and Installing the Clutch Housing Figure 10 1 4 amp WARNING To prevent serious eye injury always wear safe eye protection when doing maintenance or service Removing the Clutch Housing Figure 10 1 1 Remove the transmission as described in Section 1 In Vehicle Service 2 Remove the nuts the capscrews and the washers that fasten the clutch housing to the main case Installing the Clutch 3 Remove the clutch housing Housing 4 Use a scraper to remove all sealant NOTE material from the clutch housing and the main case Clutch housings for Design Level 1 transmissions cannot be used on De sign Level 2 transmissions Clutch housings for Design Level 2 transmis sions can be used on Design Level 1 transmissions See the chart in Figure 10 2 to choose the correct clutch housing Figure 10 2 Clutch Housing Assembly Above Centerline Clutch Release Shaft Original Design Replacement Design Part Number Level Clutch Housing Type Part Number Level SAE 1 Iron Standard SAEfH Iron Symmetrical Nodal AE 1 Aluminum Standard AE 1 Aluminum
41. Install the transmission as described in procedure described in Section 3 Section 4 Removing and Installing In Vehicle Service the Transmission 17 Fill the transmission with the specified NOTE 2 oil to the specified level See To install the air lines push the air lines Checking and Adjusting the Oil Level into the fittings until the lines touch the in Section 2 bottom of the fittings The buttons on Page 93 Section 11 Removing and Installing the Thirteen Speed Auxiliary Case Transmissions Figure 11 20 HI RANGE SPLITTER PORT PORT d WARNING To prevent serious eye injury always wear safe eye protection when doing maintenance or service Removing the Auxiliary Case Thirteen Speed Transmissions 1 If necessary remove the transmission and the output yoke as described in this section SUPPLY PORT If the auxiliary case is removed with the transmission installed in the ve NOTE hicle do the following 9 The auxiliary case must the LO a If necessary remove the output range so that the case can be removed yoke as described in this section 3 Use air gun to apply air pressure to b Remove the air from the air supply the LO range port in the piston hous system ing to put the auxiliary case into the LO range If necessary rotate the output shaft while applying air pres sure Figure 11 21 c Put a large container under the transmission Remo
42. MMOVING Ne VAIN TT Tm TM 104 Removing the Input Shaft TETTE EE 110 Removing the Main Countershafts 113 Page 2 Table of Contents Continued SUBJECT PAGE Section 12 Overhauling the Main Case Continued 104 Removing the Reverse Idler Gear 114 Rem viN Me Qil PUMP eo ebrietate uev 115 FS MMIOV IMIG TS WAG MOUS EET 116 Me PITO lt Tet 116 Installing the PTO Covers T 117 HStANNG Ne Magnets erent heer er 117 IVS TUE Ne EE ED DT 118 Installing the Reverse Idler Gear Assemblies 118 IfiStalling STE ecu Den Ud 119 Installing the Main Countershafts Patient uum eon ains 123 installing tne Mainsnaft 125 Section 13 Overhauling the Auxiliary Drive Gear 134 Disassembling the Auxiliary Drive Gear 0 134 Assembling the Auxiliary Drive Gear 136 Section 14 Overhauling the Mainshaft
43. Symmetrical Nodal A 3282 P 1030 SAE 2 A 3282 D 1044 1 2 Clutch Housing Assembly Below Centerline Clutch Release Shaft Original Design Replacement Design Part Number Level Clutch Housing Type Part Number Level A 3282 G 1021 SAE 1 lron Standard A 3282 E 1045 A 3282 H 1022 SAE 1 Iron Symmetrocal Nodal A 3282 G 1047 A 3282 J 1024 SAE 1 Aluminum Standard A 3282 F 1046 A 3282 K 1025 1 SAE 1 Aluminum Symmetrical Nodal A 3282 H 1048 Page 83 Section 10 Removing and Installing the Clutch Housing 1 Use Loctite RTV Sealant 5699 10 3 A DM HAM Hr equivalent to put a new sealant pat SURE THE BATTEBN tern for the clutch housing on the on ae AND NOT ON THE RETAINER transmission case Make sure the sealant is installed in the pattern shown in Figure 10 3 See Gasket Sealant in Section 1 2 Install the clutch housing on the trans mission case 3 Install the mounting nuts and washers on the studs on the clutch housing Tighten the nuts to 150 190 Ib ft 204 257 N m 4 Apply Loctite 222 Meritor part number 2297 B 6112 or equivalent to the threads of the capscrews that fasten the clutch housing to the main case NOTE APPLY SEALANT IN A 1 8 INCH 2MM BEAD 5 Install the mounting capscrews and washers and tighten to 65 85 lb ft 89 115 N m 6 Install the transmission as described in Section 2
44. TRANSMISSION CASE NOTE APPLY SEALANT IN A 1 8 INCH 2MM BEAD Figure 12 35 PTO COVERS TO TRANSMISSION CASE GASKET PATTERN 47 61 N m QD PUT THE PATTERN ON THE TRANSMISSION CASE PUT BEAD AROUND HOLE 3 Install the 6 hole PTO cover on the side of the case Install the mounting capscrews and washers Tighten the capscrews to 35 45 lb ft 47 61 TRANSMISSION CASE Installing the Magnets 1 Use a weak alkaline solution or a NOTE APPLY SEALANT BOLT commercial cleaning solvent to remove INA1 8INCH all oil and dirt from the case Dry the 3MM BEAD case before installing the magnets SIDE COVER 2 Remove all dirt and metal particles from the magnets Put an adhesive such as Loctite RTV Sealant 5699 Meritor Part Number 2297 A 7021 or equivalent on the bottom of the magnets Install the four magnets in the bottom of the case Figure 12 36 3 Install the main countershafts the input shaft and the mainshaft as described in this section Figure 12 36 MAGNETS Page 117 Section 12 Overhauling the Main Case Installing the Oil Pump See Figure 12 37 1 Lubricate all parts with new oil that is used in the transmission 2 Install the pump in the case Install the capscrews and the washers Tighten the capscrews to 7 10 10 10 13 N m 3 Connect the pick up tube bracket to the case Install and tighten the cap screw DA Inst
45. a towel under the low synchronizer to keep the assembly from moving when the high synchronizer is installed f Push down on the high synchro nizer so that the pins of the low synchronizer are installed in the holes in the high synchronizer Figure 16 87 Figure 16 87 g Install the low synchronizer on the hub and LO gear assembly Figure 16 88 13 If removed install the bearing cones and the splitter gear on the auxiliary countershafts See the following procedure a Put the countershaft in a press so that the auxiliary gear is toward the bottom of the press Support the countershaft on the gear Page 186 13 Speed Transmission Figure 16 88 SYNCHRONIZER ASSEMBLY LO GEAR AND HUB ASSEMBLY b Put the key in the groove on the shaft c Putthe splitter gear on the shaft Make sure the key is aligned with the slot in the gear d Put a sleeve on the gear and press the gear on the shaft Figure 16 89 Figure 16 89 MAKE SURE KEY IS INSTALLED IN GEAR e Put the rear cone on the counter shaft so that the bottom of the cone is toward the gear 13 Speed Transmission f Put a sleeve on the inner race of the cone Press the cone on the countershaft The cone is correctly installed when the bottom of the cone touches the gear Figure 16 90 Figure 16 90 g Turn the countershaft over so that the splitter gear is toward the bot tom of the press Put the fron
46. actuator pin the spring and the sleeve from the bore in the main case Figure 3 5 Installing the Slave Valve See Figure 3 4 1 Lubricate the O rings on the sleeve with a silicone lubricant such as Dow Corning 111 Silicone Grease or equivalent NOTE If the part number on the sleeve is 2245 H 1126 or 2245 A 1067 replace the sleeve with part number 2245 U 1165 2 Install the small end of the sleeve in the bore in the slave valve 3 Install the spring on the actuator pin Install the pin and spring assembly in the main case Make sure the tip on the pin is toward the slave valve Figure 3 5 Section 3 In Vehicle Service Figure 3 4 ACTUATOR PIN SLEEVE 4 On Design Level 1 Nine Speed Transmissions only install a new gasket in position on the back of the slave valve Design Level 2 Nine and Ten Speed Transmissions do not use a gasket 5 Install the slave valve and the gasket in position on the main case 6 Install the mounting capscrews and washers for the slave valve Tighten the capscrews to 85 115 Ib in 10 12 N m o Page 27 Section 3 In Vehicle Service Figure 3 RED AIR LINE Removing the Air Filter n fs and Regulator Assembly BLACKAIR QDA _ 5 LINE TO SY See Figure 3 7 PILOT PORT Figure 3 7 FILTER AND REGULATOR L Z4 SUPPLY ASSEMBLY PORT Nd LINE TO B tm LO RANGE L 7 Connect the air lines to
47. and the sleeve Wrap the lock wire around the barrel of the shaft i Put the interlock pin in the hole drilled in the end of the 1 2 shift shaft Figure 8 56 Figure 8 56 Section 8 Overhauling the Top Cover Assembly 9 Put the interlock ball in the bottom of the top bore of the first set of bores at the rear of the housing Figure 8 57 Figure 8 57 10 Make sure the low reverse sleeve and the 1 2 sleeve are in the NEUTRAL position The slots in the sleeve must be aligned NOTE On R ratio transmissions the bill of material refers to the 3 4 shift fork as the O D Overdrive shift fork and the 3 4 X bar sleeve as the O D shift sleeve 11 Assemble the 3 4 shift sleeve and shaft assembly See the following procedure NOTE The 3 4 shift sleeve shaft has a slot on one side NOTE Move the 1 2 shift shaft assembly so that the interlock ball is completely installed in the bore Move the 1 2 shaft assembly so that the 3 4 shift sleeve shaft can be installed Page 75 Section 8 Overhauling the Top Cover Assembly a Put the 3 4 shift sleeve shaft in the top bore of the housing Make sure the interlock slot on the end of the shaft is toward the rear of the housing Make sure the detent grooves in the shaft are aligned with the detent ball holes in the housing Figure 8 58 b Put the 3 4 shift sleeve in the housing Make sure the bore of the sleeve is aligned with the bore in the h
48. at the end of the shift shaft the transmission will shift into the HI range but not into the LO range check leakage at the slave valve first put the selector valve in the LO range Disconnect the air lines on the slave valve that goes to the HI range port of the piston housing Operate the vehicle to charge the air system If air is heard leaking inside the slave valve the valve is the cause of the leak check for leaks at the piston housing disconnect the air lines at the piston housing Apply air pres sure to each port one port at a time If air leaks past the piston the O ring and or the piston must be replaced If the piston does not move the shift shaft or the shift assembly is damaged Page 211 Section 19 Troubleshooting Troubleshooting Operating Conditions Cont d Transmission 1 Incorrect clutch use Make sure driver uses clutch Slips Out of the correctly Selected Gear 2 Linkage binding or does not move Lubricate repair or replace linkage In Vehicle freely Repair Clutch out of adjustment Adjust clutch Make sure clutch engages and releases correctly Remote shift linkage out of Adjust remote shift linkage adjustment Loose or damaged engine Tighten fasteners of loose mounts to and or cab mounts specified torque Replace damaged mounts Incorrect driveline angles Adjust driveline angles Weak or broken detent spring Replace detent spring in top cover in top cover assembly
49. can break and cause serious personal injury e Use a hammer and a bearing driver tool to install the upper front coun tershaft cone The cone is correctly installed when the bottom of the cone is against the countershaft Figure 12 71 Page 129 Section 12 Overhauling the Main Case Figure 12 71 f Put the cup in the bore for the upper front countershaft Use a plastic hammer to start installing the cup in the bore A WARNING Wear safe eye protection and make sure the tools are in safe condition If the tools are worn or damaged mush roomed pieces can break and cause serious personal injury g Use a hammer and a bearing driver tool to install the upper front coun tershaft cup The cup is correctly installed when the cup touches the bearing cone Figure 12 72 Page 130 Figure 12 72 h Use ahammer and a Piloted Bearing Driver to install the front cup in the bore The cup is cor rectly installed when the cup ex tends 0 125 inch 3 mm above the surface of the case CAUTION Make sure the retainer and the shims are correctly installed against the case Make sure the retainer does not push the shims against the cup or the end play will not be correct i Install the shims in the bore for the upper front countershaft bearing Replace any worn or damaged shims Make sure the slot for the oil passage on the shims are aligned with the oil passage hole Install the one of following shim
50. housing Figure 8 23 Figure 8 23 Page 62 Standard Pattern Top Cover c Put the 1 2 shift sleeve in the housing Make sure the bore of the sleeve is aligned with the bore in the housing Make sure the threaded hole in the sleeve is toward the rear of the housing Figure 8 24 d Push the shift shaft through the 1 2 shift sleeve Figure 8 24 e Put the 1 2 shift fork in the housing Make sure bend on the fork is installed toward the middle set of shift rail bores in the top cover housing Make sure the bore of the fork is aligned with the bore in the housing Figure 8 25 f Push the shift shaft through the 1 2 fork Figure 8 25 Figure 8 25 g Push the shaft through the assem bly until the holes in the fork and the sleeve are aligned with the holes in the shaft Section 8 Overhauling the Top Cover Assembly 4 After the set screws with the Loctite sealant see step 2 are tightened to the specified torque do not loosen or tighten If loosened or tightened the set screws must be removed cleaned and new sealant applied or the cap screws may loosen during operation h Install the set screw with the Loc tite sealant see step 2 that fasten the fork and the sleeve in position on the shaft Tighten the set screw to 35 45 lb ft 47 54 N m i Install the lock wire in the holes in the set screws 12 Put the interlock ball in the bottom of the top bore of the f
51. input bearing retainer Figure 9 1 INPUT BEARING RETA Figure 9 1 3 Use a scraper to remove the sealant material between the input bearing retainer and the main case NOTE A black shipping seal may be on the input shaft Remove and discard the seal 4 Remove the inner snap ring that holds the bearing on the input shaft Figure 9 2 Figure 9 2 5 Remove the bearing from the shaft The use of Owatonna tool set OTC 7070 as shown in Figure 9 3 or G amp W Tool G 38 Input Shaft Bear ing Driver as shown in Figure 9 4 or equivalent makes the removal of the bearing from the shaft easier The tool is attached to the outer snap ring on the bearing to pull the bearing from the shaft If the snap ring is not out far enough for the tool to grip pull the input shaft out until the tool can be installed on the snap ring Figure 9 5 Page 79 Section 9 Removing and Installing the Input Shaft Figure 9 3 6 Remove the spacer from the input shaft Figure 9 6 Figure 9 6 C T ia SPACER 2 LZ 525 7 O Cy C yy 7 Remove the snap ring from the gear that holds the input shaft in the gear Figure 9 7 Figure 9 7 Figure 9 5 8 Remove the input shaft Figure 9 8 Page 80 Section 9 Removing and Installing the Input Shaft 3 Install the outer snap ring in the groove Figure 9 on the bearing Figure 9 10 Figure 9 10 OUTER SNAP
52. not use a crocus cloth to polish the journal of the yoke If a crocus Cloth is used the seal will leak 7 Clean the yoke with a cleaning solvent Lubricate the journal and splines in the yoke with the oil that is used in the transmission AX CAUTION Make sure the speedometer drive gear or tone ring is correctly installed or the output shaft seal may be damaged when the yoke is installed 8 Install the soeedometer drive gear or tone ring on the yoke On 115 and 125 Series transmission use the sleeve inside the seal driver tool On 135 145 and 155 Series transmis sions remove the sleeve from the inside of the seal driver tool Page 31 Section 3 In Vehicle Service 9 Install the yoke on the output shaft Figure 3 14 Put a holding tool on the yoke Figure 3 14 4 CAUTION Do not tighten the yoke nut more than 500 Ib ft 677 N m or the output bearing Will be damaged 10 Install a new nut that fastens the yoke on the output shaft Tighten the nut to 450 500 Ib ft 610 677 N m Figure 3 14 T 11 Connect the driveshaft to the output HOLDING yoke Install and tighten the fasteners according to the specifications and procedures of the manufacturer of the vehicle 12 Operate the vehicle Make sure the oil seal does not leak Page 32 Removing and Installing the Remote Control Assembly NOTE See the recommended procedure from the manufacturer of the vehicle The following is a gen
53. of the auxiliary countershaft for damage Make sure the cup is installed correctly Page 204 Section 18 Auxiliary Countershaft End Play Adjustment d Install the correct spacer washer in h Remove the capscrews the the bore on top of the cup Make washers and the countershaft sure the tab of the washer is cover aligned with the slot in the case Figure 18 10 i Again check the end play for the auxiliary countershaft See steps 2 9 13 Use a sealant dispenser and Loctite RTV Sealant 5699 Meritor Part Number 2297 A 7021 or equivalent to put a 1 8 ind 2 mm new sealant pattern for the cover of the auxiliary countershaft in the pattern shown in Figure 18 11 See Gasket Sealant Figure 18 10 SPACER WASHER 1229 N 4538 Figure 18 11 e Install the cover for auxiliary countershaft f Install the capscrews and washers that fasten the cover to the auxiliary case SURROUND ALL g Alternately and evenly tighten the HOLES WITH SEALANT capscrews until the countershaft cover touches surface of the auxil iary cover DO NOT TIGHTEN MORE THAN 35 LB FT 47 N m 14 Install the cover for the auxiliary countershaft on the auxiliary case Install the capscrews and the washers Tighten the capscrews to 25 35 lb ft 34 47 N m Figure 18 12 o in Section 1 Page 205 Section 18 Auxiliary Countershaft End Play Adjustment Figure 18 12 NOTE Different end play measurements of each count
54. oil level is below the bottom of the hole of the fill plug add the specified oil 4 Install and tighten the fill plug to 35 50 Ib ft 48 67 N m 5 Operate the vehicle for five minutes Check for correct operation Figure 2 2 OIL LEVEL MUST BE EVEN WITH BOTTOM OF FILL PLUG HOLE Page 21 Section 2 Lubrication and Maintenance Checking the Condition of the Breather Vent Make sure the breather vent is not dam aged Remove all dirt and oil from the screen in the breather vent Figure 2 3 Figure 2 3 Checking the Torque of the Fasteners Check the torque on the following See the torque chart in Section 20 Specifications Clutch housing to engine flywheel cover housing to main case All electrical switches on the top cover housing Drain and fill plugs PTO covers to main case Auxiliary case to main case Output bearing retainer to auxiliary case Piston housing cover to auxiliary case e Auxiliary countershaft cover to auxiliary case Transmission to frame brackets Output yoke to output shaft Shift cover housing to top cover hous ing Page 22 Inspecting the Transmission for Leaks and Damage Inspect the transmission for cracks leaks and damage Make sure the leaks are transmission oil A CAUTION Repair all leaks If leaks are not re paired the transmission will be dam aged Inspect the following areas for leaks e Ihe output yoke an
55. or rope Figure 12 61 Lj MAIN DRIVE GEAR TIMING MARK COUNTERSHAFT DRIVEN GEAR TIMING MARK Page 126 10 On Design Level 1 transmissions install the upper rear bearing cup and the upper front bearing cup and cone on the countershaft See the following procedure a Put the cup in the bore for the upper rear countershaft Use a plastic hammer to install the cup in the bore b Use a hammer and a bearing driver tool to install the upper rear coun tershaft cup The cup is correctly installed when the cup is past the snap ring groove Figure 12 63 Figure 12 63 4 caution Use hand tools to rotate the forcing screw of the countershaft bearing pusher tool If power tools are used the tool will be damaged c Install Countershaft Bearing Pusher Tool Meritor Part Number 3256 D 1044 or G amp W Tool Number G 28 or equivalent on the front of the countershaft Rotate the forcing screw until the rear countershaft bearing cup is against the snap ring Figure 12 64 Section 12 Overhauling the Main Case N Q COUNTER SHAFT S BEARING PUSHER TOOL d Use a hammer a bearing driver tool to install the upper front coun tershaft cone The cone is correctly installed when the cone touches the countershaft Figure 12 65 Figure 12 65 BEARING Page 127 Section 12 Overhauling the Main Case AX WARNING Wear safe eye protection and make sure the tools are in
56. part identification on the end of the shaft is toward the front of the housing Make sure the detent grooves in the shaft are aligned with the detent ball holes Figure 8 55 b Put the 1 2 shift sleeve in the housing Make sure the bore of the sleeve is aligned with the bore in the housing Make sure the threaded hole in the sleeve is toward the rear of the housing Figure 8 55 c Push the shift shaft through the 1 2 shift sleeve Figure 8 55 d Put the 1 2 shift fork in the housing Make sure bend on the fork is installed toward the middle set of bores Make sure the bore of the fork is aligned with the bore in the housing Figure 8 55 Figure 8 55 1 2 SHIFT FORK 1 2 SHIFT SLEEVE X Bar Top Cover e Push the shift shaft through the 1 2 fork Figure 8 55 f Push the rail through the assembly until the holes in the fork and the sleeve are aligned with the holes in the shaft After the set screws with the Loctite sealant see step 2 are tightened to the specified torque do not loosen or tighten If loosened or tightened the set screws must be removed cleaned and new sealant applied or the set screws may loosen during operation g Install the set screws with the Loctite sealant see step 2 that fastens the 1 2 fork and the sleeve to the rail Tighten the set screws to 35 45 lb ft 47 54 N m h Install the lock wire in the holes in the set screws and the fork
57. parts of the auxiliary cover with the oil used in the transmis sion 2 On Design Level 1 Nine Speed Transmissions if removed install the snap ring in the groove inside the auxiliary low gear Make sure the round side of the snap ring is installed toward the gear Figure 16 21 3 Put timing marks on the auxiliary low gear Mark one tooth with paint Mark a second tooth opposite 180 the first tooth Figure 16 21 Section 16 Figure 16 21 SNAP 4 Use paint to put timing marks next to each other on two teeth of each coun tershaft low gear Make sure the mark is aligned with the stamping on the counter shaft Figure 16 22 TIMING Ke M ni STAMPING Figure 16 22 1 163 Section 16 Overhauling the Auxiliary Case 5 Assemble the output shaft and low gear assembly according to the follow ing procedure Figure 16 23 a Put the output shaft on the work bench Make sure the threaded end of the shaft is up On Design Level 1 Model 115 and 125 Transmissions install the output shaft spacer with the shoul der Make sure the spacer is installed with the large section toward the bottom of the shaft Figure 16 23 TOOTHED SPACER DESIGN Nine Speed and Ten Speed Transmissions On Design Level 1 Model 135 and 145 Transmissions install the output shaft spacer with the shoul der Make sure the spacer is installed with the large section
58. personal injury rust and dirt from the pins so that the If the auxiliary case is difficult to re auxiliary case can be removed Lubri move or the dowel pins are damaged cate the dowel pins with new oil that is used in the transmission Make sure the dowel pins are not damaged Replace damaged dowel pins after the auxiliary case is re moved use a hammer and a steel drift to remove one or both of the pins from the main case Drive the pins toward the yoke Make sure the case is se curely when the pins are removed Page 87 Section 11 Removing and Installing the Auxiliary Case 10 Remove the puller screws from the auxiliary case 11 Use an overhead hoist and brackets or a transmission jack and a bracket to remove the auxiliary case from the transmission case See the following procedure Overhead Hoist a Install lifting brackets of the auxil lary case If necessary use a pry bar to separate the case from the case enough to install a lifting bracket Figure 11 7 Connect an overhead hoist to the lifting bracket Figure 11 7 Figure 11 7 Page 88 Nine Speed and Ten Speed Transmissions c Use an overhead hoist to remove the auxiliary case from the trans mission case Transmission Jack a Remove the bottom two capscrews from the output bearing retainer Install a bracket from the transmis sion jack Figure 11 8 b Connect a transmission jack to the bracket Figure 11
59. rear bear ing cups Mark the spacers and the cups for correct installation Figure 16 8 Page 158 Nine Speed and Ten Speed Transmissions WARNING When using a hammer and a steel drift wear safe eye protection and make sure the tools are in safe condition Do not use tools that are worn or damaged mushroomed If the tools are not in safe condition pieces can break and cause serious personal injury 13 If necessary use a hammer anda steel drift to remove the shift shaft from the HI LO fork Figure 16 10 14 Remove the HI LO fork from the syn chronizer collar Figure 16 10 Figure 16 10 SHIFT SHAFT HI LO FORK 15 Remove the upper and lower auxiliary countershafts from the cover Figure 16 11 16 Remove the synchronizer assembly from the output shaft Figure 16 11 Section 16 Overhauling the Auxiliary Case Figure 16 11 AUXILIARY COUNTERSHAFTS 1 UNN oy 17 If worn or damaged disassemble the synchronizer assembly See the following procedure SYNCHRONIZER ASSEMBLY NOTE When separating the synchronizers put a towel over the synchronizers to keep the springs from flying out a Pull up on the high synchronizer to separate the high synchronizer from the low synchronizer Do not lose the springs when the synchro nizers are separated Figure 16 12 Figure 16 12 lt em gt C Page 159 Section 16 Nine Speed and Te
60. safe condition If the tools are worn or damaged mush roomed pieces can break and cause serious personal injury e Use a hammer and a bearing driver tool to install the upper front coun tershaft cup The cup is correctly installed when the cup is past the snap ring groove Figure 12 66 Figure 12 66 GROOVE f Install the thinnest snap ring 0 068 inch or 1 73 Meritor part number 1229 C 4215 in the bore for the front countershaft The snap ring is used as a gauge Figure 12 67 g Install T Handle Tool Meritor part number 3256 Y 1013 or a long capscrew in the front of the coun tershaft Figure 12 68 h Pull the countershaft and front cone assembly into the cup until the front cup is against the snap ring Figure 12 68 i Remove the T Handle Tool or the long capscrew Page 128 Figure 12 67 THINNEST SNAP RING 0 068 INCH 1 73 MM Figure 12 68 T HANDLE TOOL CUP MUST TOUCH SNAP RING NOTE The bearing cone must be installed on the rear of the countershaft 11 On Design Level 2 transmissions install the upper rear bearing cup and the upper front bearing cup and cone on the countershaft See the following procedure a Put the cup in the bore for the upper rear countershaft Use a plastic hammer to install the cup in the bore AX WARNING Wear safe eye protection and make sure the tools are in safe condition If the tools are worn or damag
61. screwdrivers and feeler gauges 17 Install the sliding collar Make sure the Slot in the collar is installed over the key Figure 14 11 Figure 14 11 LT i eel m gt lily Aull Ci It Z Mo SLOT SLIDING FOR KEY COLLAR AX CAUTION Use the correct selective washer Do not mix washers or the transmission will not operate correctly 18 Choose the correct selective thrust washer for the first or second gear See the following e Ifthe selective washers are not replaced use the original washers e Ifthe selective washers are re placed install the medium size of washer For transmissions with serial num bers LB93021753 and below use a 0 220 inch 5 60 mm washer For transmissions with serial num bers LB93021754 and above use a 0 275 inch 7 00 mm washer Section 14 Overhauling the Mainshaft 19 Remove the key Install the selective thrust washer for the first or second gear See the following Figure 14 12 a Install the washer on the shaft Make sure the smooth side is towards you b Slide the washer to the third groove above the roll pin c Move the washer so that the teeth of the washer are directly over the splines of the shaft The washer must not slide down the shaft Figure 14 12 SELECTIVE THRUST WASHER TEETH DIRECTLY OVER SHAFT SPLINES 20 Install the key in the slot where the roll pin is installed The key must touch the roll pin Figu
62. selections Figure 12 73 Section 12 Overhauling the Main Case Figure 12 73 Figure 12 74 OIL SLOT TORQUE SEQUENCE RETAINER The shims that were removed 12 Check the end play on the upper during disassembly and lower main countershafts as 0 005 inch 0 127 mm shim described in Section 17 Main Meritor part number 2803 R 2826 Countershaft End Play Adjustment A0 0075 inch 0 190 mm shim When the end play is between 0 002 Meritor part number 2803 S 2827 0 006 inch 0 050 0 152 mm go to step 13 A CAUTION 13 Install the upper reverse idler gear Make sure the retainer and the shims assembly in the top of the case See are correctly installed against the case the following procedure Make sure the retainer does not push the shims against the cup or the end play will not be correct a Install the needle bearing assembly inside the gear Figure 12 75 j Install a new retainer for the upper Figure 12 75 and lower front countershaft bear GEAR NEEDLE ings Install the Allen head cap BEARING screws Alternately and evenly ASSEMBLY tighten the capscrews to 120 Ib in 14 N m Figure 12 74 o El a ee M _ a Lor dl Jii SS a_i SPACER Page 131 Section 12 Overhauling the Main Case b Install the inner race inside the Figure 12 77 needle bearing assembly Figure 12 75 c Install a spacer washer on each
63. serial numbers LB93017866 and above rear upper countershaft bearing in the Make sure the correct part is used case Mark the snap ring for correct installation Figure 12 13 Page 107 Section 12 Overhauling the Main Case 15 On Design Level 2 Transmissions remove the fasteners for the rear upper countershaft retainer Remove the retainer Figure 12 14 Figure 12 14 RETAINER 4 cauTION Use hand tools to rotate the forcing screw of the countershaft bearing pusher tool If power tools are used the tool will be damaged 16 Install Countershaft Bearing Pusher Tool Meritor Part Number 3256 D 1044 or G amp W Tool Number G 28 or equivalent on the front of the counter shaft Rotate the forcing screw until the rear countershaft bearing cup can be removed from the case Make sure the countershaft does not push against the mainshaft Figure 12 15 If the cup is removed easily the cup is a loose fit cup Discard and replace with a press fit cup and cone assem bly Make sure the correct part is used Page 108 COUNTERSHAFT BEARING PUSHER TOOL 17 Move the upper countershaft assembly forward and to the side of the case Make sure the countershaft is sepa rated from the mainshaft assembly 18 Remove the auxiliary drive gear from the mainshaft 19 Remove the mainshaft See the fol lowing procedure a Make sure the reverse gear is against the low gear AX WARNING The main
64. the shaft plug Make sure the tip of the dial indicator is also aligned with the alignment mark on the shaft plug Figure 17 3 4 Install a torque wrench in the end of the actuator arm The torque wrench must be installed in a straight line with the actuator arm Figure 17 3 CLS b Put reference marks on the input shaft and the main case When the input shaft is rotated in this proce dure the starting and stopping positions of rotation must be in the same location Figure 17 3 c Rotate the input shaft at least four 4 complete turns in a clockwise direction Make sure the starting and stopping positions of rotation are at the same location Figure 17 4 d Set the dial indicator to zero 0 e Change the direction of force ap plied in step a to the opposite 5 Measure the upper countershaft end direction play See the following procedure TORQUE WRENCH DIAL INDICATOR f Rotate the input shaft at least four 4 complete turns in counter If you do not apply proper torque clockwise direction Make sure repeat the procedure the starting and stopping posi tions of rotation are at the same location Figure 17 5 g Record the reading on the dial indicator Page 194 Section 17 Main Countershaft End Play Adjustment 7 For Design Level 1 Transmissions if the reading is 0 002 inch or less check the following Figure 17 5 COUNTER
65. the specified torque do not loosen or tighten If loosened or tightened the set screws must be removed cleaned and new sealant applied or the set screws may loosen during operation d Install the set screw with the Loctite sealant see step 2 that fasten the fork in position on the shaft Tighten the set screw to 35 45 lb ft 47 54 e Install the lock wire in the holes in the set screw and the fork assembly Figure 8 52 LOW REVERSE SHIFT SHAFT LOW REVERSE SHIFT FORK 6 Install the neutral check shaft in the bore on the top of the housing Make sure the round end of the shaft is installed toward the low reverse shift rail Make sure the end of the shaft touches the slot in the rail Figure 8 53 Page 73 Section 8 Overhauling the Top Cover Assembly Figure 8 53 7 Put the large interlock ball in the bot tom of the middle bore of the first set of bores on the rear of the housing Figure 8 54 8 Assemble the 1 2 shift shaft assembly See the following procedure NOTE The 1 2 shift shaft is the same size as the 3 4 shift shaft and has a hole drilled through the shaft Page 74 a Bar Top Cover NOTE Move the low reverse shift shaft assem bly so that the interlock ball is com pletely installed in the bore Move the low reverse shaft assembly so that the 1 2 shaft can be installed a Put the 1 2 shift shaft in the middle bore of the housing Make sure the
66. the bores in the transmission case Remove the cups Mark each cup for correct location However if slip fit cups are installed the cups must be removed and replaced with press fit cups 12 Use a slide hammer and a puller to remove the bearing cups for the auxil iary countershaft from the case Mark the cups The cups must be installed Transmission Jack a Remove the bottom two capscrews in the original location Figure 11 27 from the output bearing retainer Install a bracket from the transmis Figure 11 27 sion jack Figure 11 26 b Connect a transmission jack to the bracket Figure 11 26 HAMMER BOTTOM TWO CAPSCREWS Page 97 Section 11 Removing and Installing the Thirteen Speed Auxiliary Case Transmissions the cups for the auxiliary counter in the main case Clean the outer shafts Design Level 2 Transmis diameter of the cups sions do not use snap rings in this On Design Level 1 Transmissions location Figure 11 28 make sure the cup is against the snap 14 Use a scraper to remove the gasket ring Figure 11 29 material from the transmission case On Design Level 2 Transmissions and the auxiliary case make sure the cup is against the step in the bore Figure 11 30 Figure 11 29 SNAP RING Installing the Auxiliary Case Thirteen Speed Transmissions NOTE The auxiliary case must be in the LO range so that the case can be installed with the gears timed correct
67. the two piece retainer Figure 13 2 5 If around retainer is used for the auxiliary drive gear clean the puller holes and install a 3 8 16 x 1 00 capscrew in the three puller holes in Figure 13 3 the bearing retainer of the auxiliary drive gear Evenly tighten the three capscrews to remove the auxiliary drive gear from the mainshaft PULLER SCREWS If necessary tap on the mainshaft with a rubber or plastic mallet to separate the gear from the mainshaft Remove the round retainer Figure 13 3 Page 134 Section 13 Overhauling the Auxiliary Drive Gear NOTE The ball bearing assembly for the auxil iary drive gear is sometimes come out when the auxiliary drive gear is re moved If necessary pull on the as sembly to separate the gear from the bearing 5 If necessary remove the ball bearing assembly from the main case Put a pry bar under the snap ring on the ball bearing assembly for the auxiliary drive gear Remove the bearing Figure 13 4 SNAP RING 6 If worn or damaged remove and replace the two O rings from the bot tom grooves of the auxiliary drive gear Inspect the teeth of the auxiliary drive gear Replace the gear if the teeth are worn or damaged Figure 13 5 Figure 13 5 8 Inspect the synchronizer surface on the auxiliary drive gear If the surface is discolored worn or damaged re place the gear and the synchronizer For synchronizer service procedures see
68. this section 2 Remove the input shaft as described in Removing the Input Shaft in this section 3 Remove the main countershafts as described in Removing the Main Countershafts in this section 4 Put a pry bar between the case and the end of the idler shaft to keep the lower reverse idler shaft from moving Remove the nut and the washer that fastens the gear on the shaft Figure 12 28 BEARING 5 Remove the reverse idler gear the two ASSEMBLY spacer washers the bearing race and the needle bearing assembly while removing the shaft Figure 12 29 Page 114 Section 12 Overhauling the Main Case Removing the Oil Pump ts Remove the auxiliary drive gear the mainshaft the input shaft and the countershafts as described in this section Remove the Allen head capscrews and washers that fasten the pump to the case Figure 12 30 Remove the bracket for the pick up tube from the case Remove the pump If necessary hit the pump with a plastic or rubber hammer to separate the pump from the case Clean the pick up screen on the tube If the tube or screen is damaged replace the pich up tube assembly If used inspect the pump to case O ring on the front of the pump If worn or damaged replace the O ring Remove the cover and inspect the pump Replace the O ring if worn or damaged Replace the pump if the rotors are worn or damaged Figure 12 31 Figure 12
69. toward the bottom of the shaft Install the small spacer on top of the spacer with the shoulder On Design Level 2 Model 115 and 125 Transmissions install the flat output shaft spacer on the shaft SNAP RING DESIGN LEVEL 1 ONLY LEVEL 1 ONLY SPACERS DESIGN LEVEL 1 SHOWN OUTPUT SHAFT DESIGN LEVEL 1 MODELS 115 AND 125 DESIGN LEVEL 1 MODELS 135 AND 145 SPACER WITH SHOULDER SHOULDER Page 164 THRUST WASHER DESIGN LEVEL 1 ONLY 0 LOW GEAR DESIGN LEVEL 2 DESIGN LEVEL 2 MODELS MODELS 115 AND 125 155 AND 165 SPACER SMALL SPACER LARGE SPACER Nine Speed and Ten Speed Overhauling the Auxiliary Case Transmissions On Design Level 1 Model 135 145 155 and 165 Transmissions install the large output shaft spacer on the shaft Install the small output shaft spacer on top of the large spacer c One Design Level 1 Nine Speed Transmissions install the toothed spacer in the low gear d One Design Level 1 Nine Speed Transmissions install the snap ring in the low gear e Install the auxiliary low gear on the output shaft Figure 16 23 f On Design Level 1 Nine Speed Transmissions install the thrust washer on top of the low gear Figure 16 23 6 Install the bearing cone on the output shaft and low gear assembly See the following procedure Figure 16 24 Figure 16 24 BEARING CONE gt WARNING A bearing heater can be use
70. transmission is disassembled or replaced and an oil cooler is used remove the cooler Remove and discard the oil from the cooler and the oil lines Install the oil cooler and the lines Tighten the fittings to the speci fied torque of the manufacturer of the vehicle Section 2 Lubrication and Maintenance 4 Install and tighten the drain plug to 35 50 Ib ft 48 67 N m 5 Clean the area by the fill plug Re move the fill plug from the side of the transmission CAUTION Use only the specified type of single weight oils Do not use multi viscosity oils or EP Extreme Pressure gear oils Multi viscosity oils and EP gear oils may damage components The use of multi viscosity or EP gear oils voids the warranty 6 Add the specified transmission oil through the hole for the fill plug Add the oil until the oil level is even with the bottom of the hole of the fill plug Figure 2 4 7 Install and tighten the fill plug to 35 50 lb ft 48 67 N m 8 Operate the vehicle for five minutes Check for correct operation Figure 2 4 OIL LEVEL MUST BE EVEN WITH BOTTOM OF FILL PLUG HOLE DRAIN PLUGS Page 23 Section 2 Lubrication and Maintenance Adjusting the Linkage for the Remote Control Assembly Cab Over Engine COE vehicles use a remote control assembly on top of the transmission Linkage connects the inner shift lever to a shift lever in the cab of the vehicle The linkage must be adjust
71. vehicle components Silicone Gasket Matenals WARNING When you apply some silicone gasket materials small amounts of acid vapor are present To prevent possible serious personal injury make sure the work area is well ventilated If the silicone gasket material gets into your eyes flush them with water for 15 minutes Have your eyes checked by a doctor as soon as possible Loctite WARNING Take care when using Loctite to avoid serious personal injury Follow the manufacturer s instructions to prevent irritation to the eyes and skin If Loctite gets into your eyes flush them with water for 15 minutes Have your eyes checked by a doctor as soon as possible Cleaning Solvents WARNING If you use solvents hot solution tanks or alkaline solutions incorrectly serious personal injury can occur To prevent serious personal injury follow the instructions supplied by the manufacturer of these products Do NOT use gasoline to clean parts Gasoline can explode and cause serious personal injury AX CAUTION e Use only solvent cleaners to clean ground or polished metal parts Hot solution tanks or water and alkaline solutions will damage these parts You can use isopropyl alcohol kerosene or diesel fuel for this purpose e If required use a sharp knife to remove gasket material from parts Take care not to damage ground or polished surfaces Table of Contents SUBJECT PAGE Section 1 General Information
72. 00 Miles 80 000 km of Vehicle Operation Approved Petroleum Base and Heavy Duty Engine Oils e Drain and replace the oil in the trans mission with approved petroleum base and heavy duty engine oils Every 500 000 Miles 400 000 km of Vehicle Operation Approved Full Synthetic Oils e Drain and replace the oil in the trans mission with approved full synthetic oils Checking and Adjusting the Oil Level See Figure 2 2 1 Make sure of the following before checking the oil level a he oil is at room temperature b Wait ten minutes after the vehicle is parked before checking the level c Make sure the vehicle is parked on a level surface 2 Clean the area around the fill plug Remove the fill plug from the side of the transmission Section 2 Lubrication and Maintenance Use only the specified type of single weight oils Do not use multi viscosity oils or EP Extreme Pressure gear oils Multi viscosity oils and EP gear oils may damage components The use of multi viscosity or EP gear oils voids the warranty 3 Check the oil level The oil level must be even with the bottom of the hole of the fill plug If foam appears when the plug is removed air has not been removed from the oil Install the plug and wait for the air to dissipate If oil flows from the hole when the plug is loosened the oil level is high Let the oil drain until the oil is at the specified level If the
73. 1 Put timing marks on the auxiliary low gear Mark one tooth with paint Mark a second tooth opposite 180 the first timing mark Figure 1 3 2 Use paint to put timing marks on two Figure 1 3 AUXILIARY LOW GEAR MARK ONE TOOTH ON EACH SIDE 180 APART TIMING MARKS Section 1 General Information teeth next to each other on each coun tershaft low gear of the auxiliary coun tershafts Make sure the marks are aligned with the stamping on the countershaft Figure 1 3 During assembly each of the two timing marks on the auxiliary low gear must be between the two marked teeth on each countershaft low gear Figure 1 4 All the timing marks must be aligned if the transmission is to operate cor rectly If the timing marks are not painted in the correct position on the gears only one set of marks will be aligned To check the alignment of the timing marks rotate the output shaft seven 7 complete revolutions All the gears must rotate For complete service procedures see Assembling the Auxiliary Case in Section 16 Overhauling the Auxiliary Case COUNTERSHAFT LOW GEAR MARK TWO TEETH OVER STAMPING MARKS 1 TK ap miii Page 9 Section 1 General Information li E E 399 TIMING MARKS ON AUXILIARY LOW GEARS zz TIMING MARKS ON COUNTERSHAFT LOW GEARS Timing Marks in Transmission Case NOTE To make s
74. 6 Figure 8 6 8 Remove the 3 4 shift shaft from the housing Remove the 3 4 shift sleeve Remove the 3 4 shift fork Figure 8 7 Standard Pattern Section 8 Top Cover Overhauling the Top Cover Assembly Figure 8 7 See Figure 8 9 3 4 SHIFT 2 SHAFT ES 9 On Design Level 1 nine speed 11 Remove the 1 2 shift shaft the 1 2 transmissions if necessary disas shift fork and the 1 2 shift sleeve from semble the 3 4 shift sleeve Remove the housing Remove the pin interlock the clip that fastens the 3 4 plunger in from the end of the 1 2 shift shaft the housing Remove the plunger Figure 8 10 Figure 8 8 Figure 8 10 porn al Figure 8 8 PLUNGER AND SPRING 1 2 SHIFT SHAFT 3 12 Remove the interlock ball from the bottom of the middle bore in the first 10 Remove the interlock ball from the set of bores in the housing bottom of the top bore of the first set of Figure 8 11 bores at the rear of the housing Figure 8 9 Page 57 Section 8 Standard Pattern Overhauling the Top Cover Assembly Top Cover Figure 8 11 Figure 8 13 REVERSE SWITCH BORES LONG PIN BREATHER VENT 13 Remove the neutral check shaft from 15 Remove the low reverse shift shaft the top cover Figure 8 12 Remove the low reverse shift sleeve and fork assembly Figure 8 14 Figure 8 12 NEUTRAL CHECK SHAFT Figure 8 14 LOW REVERSE SHIFT SHAFT FORK AND SLEEVE NOTE On standard position top cov
75. 7 Bearing Cup Auxiliary Countershaft Hear Installing 9 10 Speed 168 169 Installing 13 Speed 187 Removing 9 10 Speed 158 Removing 13 Speed 176 Bearing Cup Main Countershaft Front Lower Installing Removing 106 107 Bearing Cup Main Countershaft Front Upper Installing 126 130 Removing 108 Bearing Cup Main Countershaft Rear Lower Installing Removing Bearing Cup Main Countershaft Rear Upper Installing Removing Breather Vent 22 Page 231 Cleaning Ground Parts 19 Polished Parts 19 Rough Parts 19 Clutch Housing Installing 83 Removing 83 Corrosion 19 Description 5 Dowel Pin Installing 91 99 Removing 87 97 Drying Parts 19 End Play Auxiliary Countershaft 199 Main Countershaft 192 Identification 6 General Information 5 Gasket Installing 12 Patterns 13 14 Removing 12 opecifications 12 General Information 5 HI LO Fork Installing 9 10 Speed 170 171 Installing 13 Speed 187 188 Removing 9 10 Speed 158 159 Removing 13 Speed 175 Holding Cover Template 229 Input Shaft Installing 81 119 Removing 79 110 Inspecting Parts 15 In Vehicle Service 25 Leaks 22 209 Lubrication 20 Main Case 104 133 Main Countershaft Assembling 152 Disassembling 150 End Play 192 Installing 123 Hemoving 113 Page 232 Index Mainshaft Assembling 139 Disassembling 137 Installing 125 Removing 104 Maintenance 20 Scheduled 21 Magnets Ins
76. AUONS ERRORES 209 MOUS SION 210 Troubleshooting Operating Conditions esee 211 Table of Contents Continued SUBJECT PAGE Section 20 Specifications Rc 214 Transmissions Oil Capacities 214 Transmission Ol SCCM Ca NOMS MET 214 Fastener Torque Locations Nine Speed and Ten Speed Transmissions 215 Fastener Torque Chart Nine Speed and Ten Speed Transmissions 218 Fastener Torque Locations Thirteen Speed Transmissions 220 Fastener Torque Chart Thirteen Speed Transmissions 223 Air Line Locations Nine Speed and Ten Speed Transmissions 225 Air Line Identification Chart Nine Speed and Ten Speed Transmissions 226 Air Line Locations Thirteen Speed Transmissions 227 Air Line Identification Chart Thirteen Speed Transmissions 228 Holding Cover TRIO zl 229 RTT TETTE 230 4 Description See Figure 1 1 This publication describes the service procedures for the following Meritor trans missions Nine Speed Transmissions Jen Speed Transmissions Ilhirteen Speed Transmissions Two design levels are described in this pu
77. C add 25 Section 3 In Vehicle Service 4 caution The aluminum housing uses a gasket that is different from the gasket on the cast iron housing Use the correct gasket If the wrong gasket is used the area between the shift tower housing and the top cover housing will leak 2 Install a new gasket for the shift tower housing on the top cover housing 3 Put the shift tower housing in position on the top cover housing Make sure the bottom of the lower shift lever is correctly installed between the forks and the sleeves in the top cover hous ing Figure 3 1 4 Install the mounting capscrews and washers on the shift tower housing Tighten the capscrews to 35 45 Ib ft 48 61 N m in the sequence shown in Figure a ap Page 26 Figure 3 3 TORQUE SEQUENCE 5 Install the cover if used around the shift tower housing 6 Operate the vehicle Make sure the transmission operates correctly in all gears Removing the Slave Valve See Figure 3 4 1 Remove the air from the air supply system 2 Disconnect and mark the air lines from the slave valve by pushing on the fitting and pulling on the line 3 Remove the mounting capscrews and the washers from the slave valve Remove the slave valve On Design Level 1 Transmissions remove and replace the gasket be tween the slave valve and the case On Design Level 2 Transmissions a gasket for the slave valve is not used 4 Remove the
78. CLOCKWISE TN ROTATION Check the cover of the main coun tershaft for damage Replace damaged covers Repeat steps 1 5 MULS Check for dirt or other contami nants between the rear bearing cup DIRECTION and the case Repeat steps 1 5 OF FORCE Remove the auxiliary case and check that the cup for the main countershaft is correctly installed in the main case Make sure the cup 6 The correct end play specification is us 0 002 0 006 inch 0 050 0 152 mm is installed correctly Repeat steps 1 5 If the reading is 0 002 0 006 inch E 0 050 0 152 mm go to step 14 8 For Design Level 1 Transmissions if the reading is more than 0 006 For Design Level 1 Transmissions If inch 0 152 mm remove the 0 068 the reading is less than 0 002 inch 0 050 mm or more than 0 006 inch 0 152 mm see steps 7 8 For Design Level 2 Transmissions If the reading is less than 0 002 inch 0 050 mm or more than 0 006 inch 0 152 see steps 9 14 inch 1 73 snap ring Meritor part number 1229 C 4215 from the front bore of the main countershaft Use the reading to find the correct snap ring in the chart in Figure 17 6 Install the correct snap ring in the front bore for the main countershaft Figure 17 7 Figure 17 6 END PLAY SNAP RING MEASUREMENT THICKNESS PART INCH MM MM NUMBER COLOR 0 007 0 011 0 153 0 279 0 073 1 86 1229 D 4216 0 012 0 016 0 280 0 406 0 078 1 99
79. E KEPT OUTSIDE OF OIL SLOTS APPLY SEALANT IN A 1 8 INCH 3MM BEAD OIL ile RETAINER INPUT BEARING RETAINER TO TRANSMISSION CASE GASKET PATTERN PUT THE PATTERN ON THE INPUT BEARING RETAINER BEAD TO BE KEPT OUTSIDE OF OIL SLOTS OIL SLOT NOTE APPLY SEALANT IN A 1 8 INCH 2MM BEAD Page 13 Section 1 General Information Figure 1 10 AUXILIARY COUNTERSHAFT COVERS AND RANGE PISTON HOUSINGS TO AUXILIARY COVER GASKET PATTERN NINE SPEED AND TEN SPEED TRANSMISSION PUT THE PATTERN ON THE AUXILIARY COVER PISTON HOUSING SURROUND ALL HOLES WITH SEALANT AUXILIARY COUNTERSHAFT COVER NOTE APPLY SEALANT IN A 1 8 INCH 2MM BEAD Figure 1 11 AUXILIARY COUNTERSHAFT COVERS AND RANGE PISTON HOUSINGS TO AUXILIARY COVER GASKET PATTERN THIRTEEN SPEED TRANSMISSION PUT THE PATTERN ON THE AUXILIARY COVER PISTON HOUSING AUXILIARY COUNTERSHAFT COVER APPLY SEALANT IN A 1 8 INCH 2MM BEAD Page 14 Inspecting the Parts It is important to inspect all parts before the transmission is assembled Check all parts for wear and replace damaged parts Replacement of damaged parts now will prevent failure of the assembly later Tapered Roller Bearing Cone NOTE The bearing cup and the bearing cone must be replaced as an assembly ex cept when the cup is loose in the bore If the cup is loose in the bore install an oversize cup all other situations do Section 1 General Informati
80. IF USED NOTE If a heavy duty detent spring is used install the spring different color in the bore on the slave valve side of the transmission 9 Install a spring on top of each detent ball in the holes in the top cover Figure 7 6 Page 53 Section 8 Standard Pattern Overhauling the Top Cover Assembly Top Cover Disassembling the Standard and Forward Position Top Cover Assembly See Figures 8 1 and 8 2 Figure 8 1 SPRING Smee PLUG BREATHER VER REVERSE SWITCH PLUG BALL o 1 NEUTRAL SWITCH PLUG E 8 SHORT PIN m STANDARD POSITION 55 HOUSING FOR FORWARD POSITION HOUSING SEE BOX ROUX 22 COVER PLATE GASKET FORWARD POSITION HOUSING Page 54 Standard Pattern Section 8 Top Cover Overhauling the Top Cover Assembly Figure 8 2 LOW REVERSE FORK PLUNGER SPRING SLEEVE 1 2 SHAFT zm B 3 4 3 4 SLEEVE NEUTRAL CHECK SHAFT LOCKWIRE INSTALLATION NOTES 1 Trim excess wire to 1 4 inch 6mm 2 Bend the wire towards the capscrew 3 Twist the wire at least once between parts 4 On the 1 2 sleeve the wire can be wrapped around the shaft 5 Make sure the wire does not interfere with the movement of the rail AX WARNING Figure 8 3 NEUTRAL To prevent serious eye injury al POSITION ways wear safe eye protection when doing maintenance or service NOTE 6
81. If the washers move the gears will fall and the assembly must be disassembled THIRD FOURTH and assembled OR OVERDRIVE GEAR 12 Remove the key 13 Choose the correct selective thrust washer for the second or third gear See the following e Ifthe selective washers are not replaced use the original washers e Ifthe selective washers are re placed install the thinnest size of 10 Install the second or the third gear ded washer Make sure the snap ring is towards the third or overdrive gear Figure 14 7 For transmissions with serial num TE Mak h bers 1 893021 753 and below use Wake Sule pipe 0 216 inch 5 50 mm washer of the spacer engage the splines of the gear Figure 14 7 For transmissions with serial num bers LB93021754 and above use a 0 272 inch 6 90 mm washer 14 Install the selective thrust washer for the second or third gear See the following Figure 14 8 Figure 14 7 x f SECOND j OR THIRD GEAR C lt ET S Mii iilii s o SZ rS SELECTIVE THRUST WASHER TEETH DIRECTLY OVER SHAFT SPLINES Page 141 Section 14 Overhauling the Mainshaft a Install the washer on the shaft Make sure the chamfered side with the dot is towards you Slide the washer to the second groove above the roll pin Move the washer so that the teeth of the washer are directly over the splines of the shaft The washer must not slide down the shaft
82. JUSTING SPECIFICATIONS ROD OF VEHICLE MANUFACTURER TWO PIECE ADJUST TO ADJUSTING SPECIFICATIONS RO OF VEHICLE MANUFACTURER Page 33 Section 4 Removing and Installing the Transmission AX WARNING To prevent serious eye injury always wear safe eye protection when doing maintenance or service Removing the Transmission see the recommended procedure from the manufacturer of the vehicle to remove the transmission Some vehicles require that the engine is supported when the trans mission is removed The following is a general procedure to remove the transmis sion 1 Remove the air from the air supply system 2 Put a large container under the trans mission Remove both drain plugs and if necessary the cooler lines Drain and discard the oil Figure 4 1 Figure 4 1 OIL LEVEL MUST BE EVEN WITH BOTTOM OF FILL PLUG HOLE 3 Remove the shift lever from the trans mission If necessary remove the shift tower assembly from the transmission Page 34 4 Put marks on the yoke or the flange of the driveshaft and the output shaft of the transmission The marks on the driveshaft and the output shaft make sure the driveshaft is correctly rein stalled 5 Remove the driveshaft 6 Disconnect all the electrical connec tions if used for the back up lamp switches the neutral safety switch and the temperature indicator 7 Disconnect and mark all the air lines from the transmission 8 Disc
83. R THE O STAMPING 180 APART 2 4 aT V Vi n M A R K Sen po TIMING MARKS Figure 1 6 zu COUNTERSHAFT TIMING MARK Page 11 Section 1 General Information Gasket Sealant The transmission uses Loctite RTV Sealant 5699 Meritor Part Number 2297 A 7021 between the following components NOTE See Figures 1 9 to 1 11 for sealant patterns Clutch housing and main case PTO covers and main case Top cover and main case Auxiliary case and main case Auxiliary countershaft covers and auxiliary case Output bearing retainer on the auxiliary case e Input bearing retainer on the main case e Range piston housing to the auxiliary case AX Use Loctite RTV Sealant 5699 Meritor Part Number 2297 A 7021 as a gasket The use of any other gasket material such as a corrosive sealant can cause leaks and damage the trans mission Removing the Sealant See Figure 1 7 1 Remove the component as described in the correct section of this manual 2 Use a scraper to remove all sealant material from the surface Installing the Sealant See Figure 1 8 1 Clean the mounting surfaces with a chlorinated solvent such as Loctite Safety Solvent or equivalent Page 12 4 CAUTION Apply the sealant in a 1 8 inch 2 mmy bead If too much sealant is used the sealant that extends over the edges can break off and plug the oil passages 2 Apply Loctite
84. RING Installing the Input Shaft NOTE d CAUTION The input shaft can be installed without Put the tool or tube on the inner race of disassembling the transmission the bearing If tools are used in any 1 Lubricate all the parts in the oil that is speed on I bearing the bearing used in the transmission UE MH es 2 Align the splines of the input shaft with 4 Put the bearing over the input shaft ewe p d in the case Use a rubber or the splines inside the main drive gear Install the input shaft in the main drive plastic mallet and G amp W Tool G 35 gear Install the snap ring that holds Input Shaft Bearing Driver to install the the input shaft in the main drive gear bearing on the input shaft The bear Install the spacer on the input shaft ing is correctly installed when the snap Figure 9 9 ring touches the case Figure 9 11 Figure 9 11 Figure 9 9 NOM m SPACER NIS Section 9 Removing and Installing the Input Shaft Install the inner snap ring that fastens the bearing on the input shaft Figure 9 12 Use Loctite Master Gasket Sealant 00203 or equivalent and a sealant dispenser to put a new sealant pattern for the input bearing retainer on the case in the pattern shown in Figure 9 13 see Gasket Sealant in Section 1 Install the bearing retainer on the case Make sure the oil passage in the retainer is aligned with the oil hole in the case Figure 9 14
85. Section 16 Overhauling the Auxiliary Case Figure 13 6 9 Inspect the ball bearing Make sure the bearing rotates in the race and that the outer race is not worn or damaged Replace worn or damaged bearings Figure 13 6 Page 135 Section 13 Overhauling the Auxiliary Drive Gear Assembling the Auxiliary Drive Gear Assembly 1 Lubricate all the parts with new oil that is used in the transmission 2 f removed install two new O rings the bottom grooves of the auxiliary drive gear Make sure the O rings are lubricated with new oil that is used in the transmission Figure 13 7 Figure 13 7 3 Install the auxiliary drive gear assem bly on the mainshaft and in the rear of the case See the following Round Retainer Figure 13 8 a Install the retainer the bearing and gear assembly on the mainshaft Make sure the groove for the snap ring on the shaft is visible b Rotate the retainer so that the holes in the retainer are aligned with the bores in the case c Install and tighten the capscrews to 35 45 lb ft 47 61 N m Two Piece Retainer Figure 13 9 a Install the bearing assembly in the case over the mainshaft b Install the two piece retainer on the case Page 136 Figure 13 8 TWO PIECE RETAINER c Install and tighten the capscrews to 35 45 lb ft 47 61 N m o d Install the auxiliary drive gear on the mainshaft Make sure the groove for the snap ring on the
86. The Countershaft End Play Checking Tool is installed differently on each design 6 Install Countershaft End Play Checking Tool Meritor Part Number 3256 C 1043 or Kent Moore Tool Number J 41335 on the countershaft See the following procedure Two Hole Design Countershaft See Figure 18 3 Figure 18 3 a Put the Shaft Plug Adapter in position on the countershaft Install and tighten the screws that fasten the adapter to the countershaft b Install the short shaft plug with 5 16 inch threads into the adapter Tighten the plug Install the 3 8 inch base for two hole countershafts into one of the mounting holes for the countershaft cover Install the actuator arm so that the forked end of the arm is in the groove of the shaft plug Align the holes in the actuator arm with the hole in the base Install the pivot pin Single Hole Design Countershaft See Figure 18 4 Figure 18 4 Install the short shaft plug with 3 8 inch threads into the countershaft Tighten the plug Install the 3 8 inch base for single hole countershafts into one of the mounting holes for the countershaft cover Install the actuator arm so that the forked end of the arm is in the groove of the shaft plug Page 201 Section 18 Auxiliary Countershaft End Play Adjustment d Align the holes in the actuator arm with the hole in the base Install the pivot pin NOTE Runout measurement will not occur whe
87. Torque Chart Thirteen Speed Transmission C ontinued Torque Range Description Lb Ft Nm Output Shaft to Synchronizer Nut 7 8 14 UNF 220 260 299 352 32 HI LO Shift Fork to HI LO Shift Shaft 5 16 18 UNC 8 12 11 16 Shoulder Bolt Splitter Fork to Shaft Capscrew 7 16 20 UNF 35 45 47 61 Piston to Shift Shaft Nut 7 16 20 UNF 30 45 41 60 35 Remote Control Housing to Top Cover 35 45 47 61 Capscrew Remote Control Housing Adjusting Rod 1 2 13UNC 35 50 47 67 Jam Nut Set Screw to Linkage Nut to Linkage Nut opeen NN ee to Linkage Nut Set Screw NOTES fasteners with threads 1 4 inch 7mm or smaller put Loctite 222 Meritor Part Number 2297 B 6112 or equivalent on the threads On fasteners with threads greater than 1 4 inch 7mm threads or smalller put Loctite 242 Meritor Part Number 2297 V 2430 or equivalent on the threads Put a new application of Loctite or equivalent if any of the following occur a Anew fastener is installed b The sealant is removed from the threads C The fastener is removed the third time from the transmission Q Requires Loctite amp 242 Meritor Part Number 2297 V 2430 or equivalent and lockwire After the capscrews are tightened to the specified torque do not loosen or tighten the capscrews If the cap screws are loosened or tightened the capscrews must be removed cleaned and new sealant applied or the capscrews may loosen during operation When insta
88. W OR gear on the mainshaft Figure 12 6 GEAR FIRST GEAR 1 7 Slide the clutch collar into the low or first gear Move the reverse gear against the low or first gear Figure 12 7 m T T c e Ll T P 105 Section 12 Overhauling the Main Case 8 Put a pry bar between the case and the end of the idler shaft to keep the reverse idler shaft for the upper coun tershaft from moving Remove the nut and the washer that fastens the gear on the shaft Figure 12 8 Figure 12 8 PRY UPPER IDLER GEAR qp rmn 9 Remove the upper reverse idler shaft from the rear of the case Remove the reverse idler gear the two spacer washers the bearing race and the needle bearing assembly while remov ing the shaft Figure 12 9 Figure 12 9 NEEDLE BEARING ASSEMBLY uy JJ gt d J o E 1 IK HR iiis Page 106 The mainshaft must be supported when the countershaft is serviced If not supported the timing marks fall out of alignment The weight of the mainshaft will also damage the thrust washers between the gears 10 Install the auxiliary drive gear and bearing assembly so that the mainshaft is supported in the case 11 On Design Level 1 Transmissions remove
89. afts NOTE Check the end play on one countershaft at a time 1 Put the transmission in NEUTRAL Figure 17 1 Figure 17 1 NEUTRAL POSITION 2 Install Countershaft End Play Checking Tool Meritor Part Number 3256 C 1043 or Kent Moore Tool Number J 41335 on the upper countershaft See the following procedure Figure 17 2 Figure 17 2 Put the Shaft Plug Adapter in position on the countershaft Install and tighten the screws that fasten the adapter to the countershaft Install the short shaft plug with 5 16 inch threads into the adapter Tighten the plug Install the 3 8 inch base into one of the mounting holes for the clutch housing Install the actuator arm so that the forked end of the arm is in the groove of the shaft plug Align the holes in the actuator arm with the hole in the base Install the pivot pin Page 193 Section 17 Main Countershaft End Play Adjustment NOTE a Use the torque wrench to apply a Runout measurement will not occur force of 25 Ib ft or 300 Ib in 34 when the output shaft is rotated if the N m in one direction o dial indicator and the Countershaft End Figure 17 4 Play Checking Tool are correctly installed If runout occurs make sure Figure 17 4 the tip of the dial indicator and the CLOCKWISE alignment mark on the shaft plug ROTATION are aligned 3 Install a dial indicator so that the tip of the indicator is in the center of
90. all the main countershafts the input shaft and the mainshaft as described in this section Figure 12 37 Installing the Reverse Idler Gear Assemblies 1 Lubricate all parts with new oil that is used in the transmission 2 Install the needle bearing assembly inside the lower reverse idler gear Figure 12 38 3 Install the inner race inside the needle bearing assembly Figure 12 38 4 Install a spacer washer on each side of the reverse idler gear Figure 12 38 Page 118 Figure 12 38 BEARING ASSEMBLY RACE 5 Put the lower reverse idler gear in position in the bottom of the case 6 From the auxiliary cover side of the transmission case install the shaft through the reverse idler gear assembly 7 Install the nut and the washer that fastens the lower reverse idler gear assembly in the case Hold the end of the shaft with a screwdriver Tighten the nut to 75 100 Ib ft 101 135 N m Figure 12 39 Figure 12 39 Section 12 Overhauling the Main Case 8 Install the countershafts the input shaft and the mainshaft as described in this section The procedure to install the upper reverse idler gear assembly is in Installing the Mainshaft in this section Installing the Input Shaft 1 Use paint to put a timing mark on one tooth of the main driven gear on the input shaft Put another paint mark directly opposite 180 the first mark Figure 12 40 Figure 12 40
91. ame location Figure 18 6 Section 18 Auxiliary Countershaft End Play Adjustment Figure 18 7 COUNTER CLOCKWISE Kl DIRECTION OF FORCE d Set the dial indicator to zero 0 e Change the direction of force ap plied in step a to the opposite direction f Rotate the output shaft at least four 4 complete turns in a counter clockwise direction Make sure the starting and stopping posi tions of rotation are at the same location Figure 18 7 g Record the reading on the dial indicator 10 The correct end play specification is 0 002 0 006 inch 0 050 0 152 mm If the reading is less than 0 002 inch 0 050 mm or there is no reading on the dial indicator see step 11 If the reading is 0 007 inch 0 177 mm or more see step 12 If the reading is 0 002 0 006 inch 0 050 0 152 mm the end play is correct See step 13 11 If the reading is less than 0 002 inch 0 050 mm or there is no reading move the cup 0 125 inch 3 mm to ward the outer surface of the case Use a yoke bar puller bridge washer and a long 5 16 inch x 18 capscrew to move the cup Figure 18 8 Figure 18 8 COUNTERSHAFT YOKE WASHER p C2 mmis t TAa c CAPSCREW If the reading is less than 0 002 inch 0 050 mm or there is no reading check the following Check the cover of the auxiliary countershaft for damage Replace damaged covers Repeat steps 6 9 Check for dirt or other co
92. andard position X bar top cover oH tea assembly and the forward position X top cover assembly use different hous ings The forward housing also uses a plate and a gasket installed over the detent balls and springs 1 Remove the top cover assembly as described in this section Make sure the top cover assembly is in the NEU TRAL position Figure 8 34 Page 67 Section 8 X Bar Overhauling the Top Cover Assembly Top Cover 2 On forward top covers remove the Figure 8 36 REVERSE capscrews that fasten the detent SWITCH BORES spring cover plate if installed to the top cover assembly Remove the plate and the gasket NOTE If a heavy duty detent spring is used the spring different color in the bore on the slave valve side of the transmis sion 3 If installed remove the three detent Springs and balls from the top of the housing Figure 8 35 LONG PIN Figure 8 35 e eo 5 If necessary remove the breather from the top of the cover Figure 8 37 6 Remove the neutral safety switch or plug Remove the short pin from the bore Figure 8 37 Figure 8 37 NEUTRAL SAFETY SWITCH BORE NOTE On standard position top cover assem blies two reverse switches may be used On forward position housings one reverse switch Is used 4 Remove the reverse switches or plugs from the housing Remove the long CAUTION ins f h Figure 8 36 Do not damage the mac
93. ant 5699 Meritor Part Number 2297 A 7021 or equivalent to make a 1 8 inch 2 mm sealant pat tern for the range cylinder housing See Figure 16 45 for the sealant O RINGS pattern See Installing the Sealant in section 1 Install the range cylinder housing on the auxiliary cover Page 172 Nine Speed and Ten Speed Section 16 Transmissions Overhauling the Auxiliary Case 28 Install the piston on the shaft in the Figure 16 47 RANGE range cylinder Install the nut that CYLINDER fastens the piston on the shaft Tighten the nut to 35 50 Ib ft 48 67 Figure 16 47 29 Install the gasket between the range cylinder cover and the range cylinder housing Install the cover 30 Install the capscrews and the washers the fasten the range cylinder cover to the auxiliary cover Tighten the cap screws to 35 45 lb ft 47 61 N m 31 Put the auxiliary cover in the LO range 32 Clean the outer diameter of the cups for the front bearing cones of the auxiliary countershafts Put the cups in the correct bores in the transmission case Figure 16 48 Page 173 Section 16 13 Speed Overhauling the Auxiliary Case Transmission Disassembling the Auxiliary Case Thirteen Speed Transmissions See Figure 16 49 Figure 16 49 CASE CUP AND CONE ASSEMBLY PISTON HOUSING AUXILIARY CASE 2 LE f COUNTER SHAFT ASSEMBLY SPLITTER FORK HI LO FORK SYNCHRONIZER OUTPUT ASSEMBLY
94. ar assembly from the mainshaft Page 125 Section 12 Overhauling the Main Case 5 Remove the snap ring that fastens the CAUTION reverse gear to the mainshaft Slide The mainshaft must be supported when the reverse gear forward until the gear the countershaft is serviced If not touches the low gear Figure 12 60 supported the timing marks fall out of 6 Install the sliding collar on the front of alignment The weight of the mainshaft the mainshaft Figure 12 60 Will also damage the thrust washers between the gears Figure 12 60 8 Install the auxiliary drive gear and COLLAN bearing assembly so that the mainshaft is supported in the case 9 Align the timing marks on the main drive gear of the input shaft with the timing marks on the upper counter shaft Use the T Handle Tool or the long capscrew to move the counter shafts Figure 12 62 Remove the T Handle Tool or long capscrews from the countershafts 1 it tpr LU jj li rm Li LL O REVERSE GEAR MUST TOUCH LOW GEAR NOTE 7 Put lifting hooks or a rope under the The bearing cone must be installed on mainshaft assembly Install the main the rear of the countershaft shaft assembly in the case Make sure the front of the mainshaft is installed in Figure 12 62 the bushing in the input shaft Tempo 25 install the auxiliary drive gear to support the rear of the mainshaft Remove the lifting hooks
95. assembly Transmission Worn pads on shift fork Replace shift fork Slips Out of the Worn teeth in sliding clutch Replace sliding clutch Selected Gear Worn fork slot on sliding clutch Replace sliding clutch Remove and Broken key on mainshaft Replace key and or mainshaft Disassemble Twisted mainshaft Replace mainshaft Transmission Transmission Incorrect vehicle operation Make sure driver operates vehicle Is Hard to Shift correctly or Unable to Clutch out of adjustment Adjust clutch Make sure clutch Shift Into the engages and releases correctly Selected Gear Remote shift linkage binding Lubricate repair or replace remote In Vehicle or unable to move shift linkage Repair Loose and or damaged cab Tighten fasteners of loose mounts to and or engine mounts specified torque Replace damaged mounts Detent spring too strong or broken Replace detent spring Transmission Bent shift shaft in top cover Replace shift shaft Is Hard to Shift assembly or Unable to Burr on shift shaft in top cover Replace shift shaft Shift into the assembly Selected Gear Cracked top cover assembly Replace top cover assembly Remove and Twisted mainshaft Replace mainshaft Disassemble Broken key on mainshaft Replace key and or mainshaft Transmission Broken or bent shift fork on Replace fork sliding clutch Transmission Driver does not operate vehicle Make sure driver operates vehicle G
96. available See Figure 7 1 Standard position top cover with a standard shift pattern Standard position top cover with an x shift pattern 0 Forward position top cover with a standard shift pattern Figure 7 1 STANDARD POSTION TOP COVER STANDARD SHIFT PATTERN FORWARD POSITION TOP COVER STANDARD SHIFT PATTERN INDICATES X BAR 0 Forward position top cover with an X shift pattern Standard position top covers have the detent balls and springs under the shift lever housing Forward position covers have the de tent springs and balls under a plate behind the shift lever housing Top covers with an X shift pattern have a stud and a nut that fastens the rocking lever assembly to the top cover 1 Shift the transmission into the NEU TRAL position 2 Remove the transmission if neces sary and the shift lever and tower assembly as described in Section 3 In Vehicle Service STANDARD POSTION TOP COVER X SHIFT PATTERN FORWARD POSTION TOP COVER X SHIFT PATTERN Section 7 Removing and Installating the Top Cover Assembly NOTE Figure 7 2 If a heavy duty detent spring is used DETENT the spring different color is in the bore SPRING on the slave valve side of the transmis sion 3 Remove the three detent springs from the top cover from the holes in the top cover Figure 7 2 TUS 3 dcs 4 Use a magnet to remove a detent ball from the each of the three h
97. b Slide the washer to the fifth groove above the roll pin c Move the washer so that the teeth of the washer are directly over the splines of the shaft The washer must not slide down the shaft Section 14 Overhauling the Mainshaft SELECTIVE THRUST WASHER TEETH DIRECTLY OVER SHAFT SPLINES 30 Install the key in the slot where the roll 32 pin is installed Make sure the key touches the roll pin Figure 14 21 Figure 14 21 31 Install the spacer on top of the washer Figure 14 22 33 SPACER e A ern qum Install the reverse gear on the shaft Make sure the splines in the gear engage the teeth in the spacer and the snap ring is against the spacer Figure 14 23 Install the snap ring in the second snap ring groove from the top of the main shaft Make sure the opening of the snap ring is opposite 1809 the key Figure 14 24 Page 147 Section 14 Overhauling the Mainshaft Figure 14 24 SNAP RING Figure 14 26 TW 180 FROM ROLL PIN AUXILIARY SNAP RING DRIVE GEAR 34 Install the thrust washer for the auxil 37 Check the clearance between the lary drive gear on the mainshaft in the auxiliary drive gear and the reverse second groove from the top of the gear See the following procedure mainshait Figure 14 25 a Lift on the auxiliary drive gear and Figure 14 25 push on the reverse gear Make THRUST sure the auxiliary drive g
98. blication Design Level One This applies to transmissions with serial numbers LB93001999 and below Snap rings are used to keep the tapered roller bearings in the case Design Level Two This applies to transmissions with serial numbers LB93002000 and above Retainer plates are used to keep the tapered roller bearings in the case Figure 1 1 NINE SPEED TRANSMISSION TEN SPEED TRANSMISSION Section 1 General Information The main case which includes the main shaft the main countershafts the input shaft the reverse idler gear and the op tional oil pump are the same for all trans missions The auxiliary case is the same design for nine speed and ten speed transmissions while the auxiliary case for the thirteen speed transmission is different The thir teen speed transmission uses a different case piston housing and output shaft assembly The thirteen speed transmis sion also uses a splitter gear set in addition to a Hl and LO range gear set The input torque from the engine is distrib uted by two countershafts and one main shaft An auxiliary case provides the LO and HI ranges of operation Tapered roller bearings are used to sup port the countershafts in the main trans mission case and the auxiliary section THIRTEEN SPEED TRANSMISSIONS Page 5 Section 1 General Information An air shift system is used to select the LO or HI range of operation on all transmis sions and the DIR and OD
99. case from the transmission case Figure 11 24 Figure 11 24 PULLER Page 96 d WARNING When using a hammer and a steel drift wear safe eye protection and make sure the tools are in safe condition Do not use tools that are worn or damaged mushroomed If the tools are not in safe condition pieces can break and cause serious personal injury If the auxiliary case is difficult to re move or the dowel pins are damaged use a hammer and a steel drift to remove one or both of the pins from the main case Drive the pins toward the yoke Make sure the case is se cure when the pins are removed 10 Remove the puller screws from the auxiliary case 11 Use an overhead hoist and brackets or a transmission jack and a bracket to remove the auxiliary case from the transmission case See the following procedure Overhead Hoist a Install lifting brackets of the auxil lary case If necessary use a pry bar to separate the case from the case enough to install a lifting bracket Figure 11 25 b Connect an overhead hoist to the lifting bracket Figure11 25 c Use an overhead hoist to remove the auxiliary case from the trans mission case Section 11 Thirteen Speed Removing and Installing Transmission the Auxiliary Case Figure 11 25 Use the transmission jack to re move the auxiliary case from the transmission case NOTE Sometimes the bearing cups for the auxiliary countershafts will remain in
100. ced use the original washers fthe selective washers are re placed install the medium size of washer For transmissions with serial num bers LB93021753 and below use a 0 220 inch 5 60 mm washer For transmissions with serial num bers LB93021754 and above use a 0 275 inch 7 00 mm washer 6 Install the selective thrust washer for the third or overdrive gear See the following Figure 14 4 a Install the washer on the shaft Make sure the smooth side is towards you b Slide the washer to the groove above the roll pin c Move the washer so that the teeth of the washer are directly over the splines of the shaft The washer 9 must not slide down the shaft NOTE The key will be removed and installed during this procedure Mark the groove where the roll pin is installed 7 Install the key in the slot where the roll pin is installed Make sure the key touches the roll pin Figure 14 5 8 Install the spacer on top of the washer Figure 14 5 Page 140 Figure 14 4 SELECTIVE THRUST WASHER TEET DIRECTLY OVER SHAFT gt z Md Bois Install the third or the overdrive gear on the shaft Make sure the splines in the gear engage the teeth on the spacer and the snap ring is against the spacer Figure 14 6 Section 14 Overhauling the Mainshaft Figure 14 6 A CAUTION Make sure the selective washers do not move when the key is removed
101. cedure Figure 4 10 a Put the transmission so that the input shaft is aligned with the pilot bearing b Move the input shaft into the clutch housing Make sure the two tips of the release fork are installed be tween the release bearing assem bly and the clutch cover c If necessary rotate the output shaft of the transmission to align the splines on the input shaft with the teeth in the hubs of the clutch discs Mi TIPS OF RELEASE FORK MUST BE INSTALLED BETWEEN RELEASE BEARING AND CLUTCH 16 17 18 19 20 21 22 23 Section 4 Removing and Installating the Transmission d Push the transmission against the flywheel housing Install the capscrews that fasten the clutch housing on the transmission to the flywheel housing Tighten the capscrews to the specified torque and the sequence specified by the manu facturer of the vehicle Align the transmission with the brack ets on the frame Install the fasteners that hold the transmission on the brackets Tighten the fasteners to the torque specified by the manufacturer of the vehicle Remove the transmission jack or lifting device from the transmission If a hydraulic assist system is used for the clutch install the slave cylinder in the bracket on the transmission Con nect the push rod to the release lever on the transmission Connect the spring to the release lever Connect the clutch linkage to the release lever on the t
102. d the oil seal in the output bearing retainer on the auxiliary case The PTO covers on the main case The auxiliary case to main case The main case and the clutch housing The clutch housing to flywheel hous ing The auxiliary countershaft covers The slave valve to the main case The shift lever and tower assembly to the top cover The top cover to the main case The fill and the drain plugs The output bearing retainer to the auxiliary case e The input bearing retainer to the main case e Speedometer bore or electronic speed pick up in the output bearing retainer Draining and Replacing the Transmission Oil NOTE Drain the oil when the transmission is hot 1 Make sure the vehicle is parked ona level surface Put a large container under the transmission Put a screen on top of the container NOTE Meritor recommends replacing the magnetic drain plug each time the oil is changed Use the correct part Pipe plugs will leak if used as a drain plug The magnetic drain plug can be reused if after cleaning the plug has a mini mum pick up capacity of 1 5 pounds 0 7 kilograms of low carbon steel 2 Remove the drain plugs from the bottom of the transmission Drain and discard the oil Inspect the O rings on the drain plugs Replace worn or damaged O rings Inspect the screen on top of the con tainer for metal particles and damaged particles Service the transmission as necessary If the
103. d to install the bearing cone Follow the instruc tions of the manufacturer of the bearing heater The heated cones can burn you Section 16 a Put the output shaft and low gear assembly on a press Support the shaft on the bottom of the shaft Make sure the threads on the shaft are toward the top of the press b Install a bearing cone on the shaft Make sure the large diameter of the gear is toward the cone c Puta sleeve on the cone Press the cone on the shaft until the cone touches the thrust washer or the low gear Make sure the gear and the bearing cone rotates on the shaft d Install the spacer on the shaft Figure 16 25 Figure 16 25 SPACER ITE CN CERDO 7 If removed install the bearing cups for the output shaft in the auxiliary cover See the following procedure a Put the cover in a press so that the outside is toward the top of the press Support the cover under the output shaft bore Figure 16 26 b Put the inner bearing cup in the cover Make sure the letters on the cup are toward you Install a sleeve or a bearing installation tool on the race of the bearing Figure 16 26 Page 165 Section 16 Nine Speed and Ten Speed Overhauling the Auxiliary Case Transmissions Figure 16 26 Figure 16 28 INNER 8 If removed install the bearing cones c Press the inner cup into the cover on the auxiliary countershafts See the Figure 16 26 9 fol
104. device to the lifting Figure 11 36 9 bracket s 12 Install the mounting capscrews and washers for the auxiliary case Tighten the capscrews to 35 45 10 47 61 N m Figure 100 Section 11 Thirteen Speed Removing and Installing Transmission the Auxiliary Case Figure 11 37 HI RANGE PORT SPLITTER PORT RANGE PORT SUPPLY PORT 13 Check and adjust the end play of 15 Connect the following air tubes Fig each auxiliary countershait Do the ure 11 37 procedure described in Section 18 Auxiliary Countershaft End Play a BLACK tube to the LO range port Adjustment When the correct end on the piston housing play of 0 002 0 006 inch 0 050 0 152 b BLUE tube to the HI range port on mm is obtained go to step 14 of the piston housing cover this procedure c RED tube to the supply port of the filter and regulator assembly Splitter tube to the fitting on the piston housing cover 14 If removed install the filter and regula d tor assembly See the procedure in Section 3 In Vehicle Service 16 Install the transmission as described in NOTE this section To install the air lines push the air lines 17 Fill the transmission with the specified into the fitting until the lines touch the oil to the specified level See Check bottom of the fittings The buttons on ing and Adjusting the Oil Level in the top of the fittings automatically lock Section 2 the air lines in pos
105. e the tools are in safe condition Do not use tools that are worn or damaged mushroomed If the tools are not in 6 Lubricate the dowel pins with new oil safe condition pieces can break and that is used in the transmission cause serious personal injury 7 Connect a lifting bracket to the 5 f the dowels have been removed use auxiliary case a steel drift and a hammer to install the dowels Install the dowels from the back of the main case flange Install the dowels until the end of the dowels are 2 5 inches 64 mm from the flange Figure 11 14 If a transmission jack is used remove the bottom two capscrews from the output bearing retainer Use capscrews to connect a bracket for the jack to the retainer Figure 11 15 Page 91 Section 11 Nine Speed and Removing and Installing Ten Speed the Auxiliary Case Transmissions Figure 11 15 NOTE The auxiliary section must be in the LO range and the main case must be in gear to install the auxiliary case 9 Install the auxiliary case Make sure the dowel holes in the auxiliary case are aligned with the dowels in the main case and that the auxiliary case is evenly installed on the dowels Rotate the input shaft so that the teeth on the auxiliary drive gear align with the teeth on the countershaft driven gears BOTTOM TWO Figure 11 17 CAPSCREWS Figure 11 17 lf an overhead hoist is used connect brackets to the bores for the transmis sion case capscrews
106. e 16 83 a Install the shaft in the fork Make sure the holes in the shaft and the fork are aligned Page 184 13 Speed Transmission Install the capscrew Tighten to 35 45 lb ft 47 61 Install a new lock wire in the cap screw and fork Figure 16 83 LOCKWIR SPLITTER FORK 12 Assemble the LO gear and synchro nizer assembly a Install the snap ring in the groove inside the LO gear and hub assem bly Make sure the round side of the snap ring is installed away from the gear Install the washer inside the gear Figure 16 84 Figure 16 84 WASHER b Section 16 Overhauling the Auxiliary Case Put the low synchronizer on the table so that the pins are toward yOu Install the synchronizer collar over the pins on the low synchronizer cone Make sure the chamfered holes in the collar are over the pins Make sure the cone touches the collar Figure 16 85 Figure 16 85 d LOW SYNCHRONIZER Install the springs in the holes in the high synchronizer Put grease on the springs Use a multi pur pose lubricating grease with NLGI Number 2 rating Figure 16 86 Figure 16 86 SPRING Page 185 Section 16 Overhauling the Auxiliary Case e Install the high synchronizer on the pins of the low synchronizer cone Move the high synchronizer so that the springs are against the side of the pins of the low synchronizer Figure 16 87 NOTE Put
107. e RTV Sealant 5699 Meritor Part Number 2297 A 7021 with a sealant dispenser to one sur face Apply the sealant in a continu ous pattern with a 1 8 inch 2 mm bead Make sure the bead encircles any fastener holes 3 Install the component as described in the correct section of this manual Figure 1 7 SEALANT DISPENSER Figure 1 9 Section 1 General Information AUXILIARY COVER TO TRANSMISSION CASE GASKET PATTERN e PUT THE PATTERN ON THE AUXILIARY COVER TRANSMISSION CASE GASKET PATTERN TRANSMISSION CASE BOLT HOLE CLUTCH HOUSING TO TRANSMISSION CASE GASKET PATTERN PUT THE PATTERN ON THE TRANSMISSION CASE MAKE SURE THE PATTERN IS ON THE TRANSMISSION CASE AND NOT ON THE RETAINER NOTE APPLY SEALANT IN A 1 8 INCH 2MM BEAD SHIFT BAR HOUSING TO TRANSMISSION CASE GASKET PATTERN PUT THE PATTERN ON THE TRANSMISSION CASE FOUR HOLES SURROUNDED BY SEALANT NOTE APPLY SEALANT IN A 1 8 INCH TRANSMISSION CAS AMAN BEAD AUXILIARY COVER GASKET PATTERN REAR COVER BOLT HOLE TE APPLY SEALANT IN A 1 8 INCH 2MM BEAD PTO COVERS TO TRANSMISSION CASE GASKET PATTERN PUT THE PATTERN ON THE TRANSMISSION CASE NOTE APPLY SEALANT IN A 1 8 INCH 2MM BEAD TRANSMISSION CASE ity PUT BEAD AROUND HOLE BOTTOM COVER SIDE COVER OUTPUT BEARING RETAINER TO AUXILIARY COVER GASKET PATTERN PUT THE PATTERN ON THE OUTPUT BEARING RETAINER BOLT HOLE X IL SLOT J TO B
108. e and discard the nut and washer that fasten the LO gear and synchronizer assembly to the output shaft Figure 16 56 Figure 16 56 Figure 16 58 C LO GEAR AND HUB ASSEMBLY 15 Remove the capscrews and washers that fasten the holding plates on the countershafts and cover DO NOT CHANGE THE POSITION OF THE AUXILIARY COVER IN THE REPAIR ein _ 17 Remove the LO gear and synchronizer l assembly See the following proce 16 On Design Level 1 Transmissions dure Figure 16 59 Remove the snap rings that fastens the upper and lower auxiliary counter shafts in the cover Remove the rear bearing cups DO NOT CHANGE THE a Move the splitter shaft so that the splitter fork will not touch the LO gear during removal POSITION OF THE COVER IN THE b Move each countershaft away from REPAIR STAND Mark the snap rings the LO gear and cups for correct installation c Liftthe LO gear and coupling Figure 16 58 asssembly out of the cover Page 177 Section 16 13 Speed Overhauling the Auxiliary Case Transmission LO GEAR Figure 16 59 AND SYNCHRONIZER ASSEMBLY SHAFT d Remove the splitter fork and shaft assembly and the clutch collar as an assembly Figure 16 60 18 Remove the upper and lower auxiliary countershafts from the cover Figure 16 60 Figure 16 60 SPLITTER FORK AND SHAFT COUNTERSHAFTS 19 If worn or damaged disassemble the LO gear and synchroniz
109. e shaft 8 Inspect the oil seal in the output bear ing retainer If the seal is worn or damaged remove and replace the seal Figure 15 53 9 If a mechanical soeedometer is used inspect the speedometer bushing inside the output bearing retainer If SHOULDER BOLT worn or damaged remove the bush AND NUT ing Figure 16 53 WARNING When using a hammer and a steel drift wear safe eye protection and make sure the tools are in safe condition Do not use tools that are worn or damaged BUSHING mushroomed If the tools are not in safe condition pieces can break and cause serious personal injury Figure 16 53 12 If necessary use a hammer and a brass drift to remove the shift shaft from the HI LO fork Figure 16 55 13 Remove the HI LO fork from the syn chronizer collar Figure 16 55 OIL SEAL Figure 16 55 10 Move the assembly in the repair stand so that the inside of the cover is toward you NOTE If a pin and a clip is used to fasten the HI LO fork to the shift shaft replace With a nut and shoulder bolt during assembly 11 Remove the shoulder bolt and the nut or pin and clip that fastens the HI LO fork to the shift shaft Figure 16 54 Page 176 13 Speed Section 16 Transmission Overhauling the Auxiliary Case NOTE Figure 16 57 Install a capscrew to fasten the plate to the cover to keep the gears from mov ing when the nut is removed Figure 57 14 Remov
110. e the clip and pin assembly from the lever Remove the bush ings Figure 5 2 b If a bolt and nut is used remove the nut and the bolt c Remove the upper shift lever from the lower shift lever Figure 5 2 Figure 5 2 3 Remove the clamps that fasten the boot to the housing Remove the boot from the housing and the lower shift lever Page 42 4 Put the assembly in a vise with brass jaws Make sure the inside of the housing is away from you 5 Remove the snap ring that fastens the upper retainer plate and the lever in the housing Figure 5 3 Figure 5 3 6 Remove the set screws from the side of the housing Remove the lower retainer from the housing Figure 5 4 Figure 5 4 Section 5 Overhauling the Shift Lever and Tower Assembly 7 Lift on the lever to remove the lever and the upper retainer plate from the housing Figure 5 5 NOTE Two or three spring washers may be used in the housing Make sure the same number of washers are installed 8 Remove the spring washers from the housing Figure 5 6 9 Inspect all parts See Repairing or Replacing the Parts in Section 1 Figure 5 5 RETAINER 74 PR S Figure 5 6 Assembling the Aluminum Gear Shift Lever and Tower Housing See Figure 5 1 NOTE If an aluminum housing is being re placed replace the entire assembly with a cast iron shift tower housing 1 Put the housing in a vise with brass ja
111. eal leak On New Transmissions The following conditions can be found on new transmissions and are not considered oil leaks e Lubricants applied to the yoke during assembly can make the seal area appear moist or leaking All output seals are pre lubed with grease that melts at low temperatures When the grease melts it comes out of the seals and the seals only appear to be leaking Vibration When checking a noise or a vibration find out when the problem occurs Section 19 Troubleshooting When the transmission is in NEUTRAL or in gear During upshifts or downshifts In all gears or specific gears In the HI range or the LO range In the DIR range or the OD range Thirteen Speed Transmission Only During coast or acceleration e With the vehicle loaded or unloaded Noise If a noise is the problem find out the sound of the noise Growling humming or grinding Hissing thumping or bumping Rattles squealing Whining Operation Problems When the transmission is not operating correctly find out when the problem occurs In NEUTRAL or in gear During upshifts or downshifts In the HI range or the LO range In the DIR range or the OD range Thirteen Speed Transmission Only Also find out what the transmission does during the problem Does not stay in the selected gear Does not stay in the selected range Does not select all gears Does not select all ranges Overheats
112. ear Page 149 Section 15 Overhauling the Main Countershafts Disassembling the Upper and the Lower Main Countershaft Assemblies See Figure 15 1 Figure 15 1 FIRST GEAR aD SECOND GEAR SECOND GEAR _ Es THIRD GEAR THIRD GEAR OR 4 OVERDIVE GEAR APPLICATIONS 9 SPEED DIRECT DRIVE TRANSMISSIONS 4 9 SPEED RATIO OVERDRIVE TRANSMISSIONS 2 9 SPEED A RATIO OVERDRIVE TRANSMISSIONS 10 SPEED OVERDRIVE TRANSMISSIONS 3 9 SPEED RATIO OVERDRIVE TRANSMISSIONS 9 SPEED DESIGN LEVEL 1 TRANSMISSIONS 7 13 SPEED TRANSMISSION Page 150 Section 15 Overhauling the Main Countershaft that fits inside the diameter of the WARNING countershaft Press the counter To prevent serious eye injury always shait from the cone Discard the cone Figure 15 3 Figure 15 3 wear safe eye protection when doing maintenance or service NOTE The upper and lower main counter shafts are serviced in the same way NOTE See Figure 15 1 to identify the compo nents of the countershaft assembly for the transmission models 1 If necessary remove the front and rear countershaft bearings See the follow ing a Puller Method Rear Bearing Put a step plate on the counter shaft Install a puller tool so that the jaws of the puller are under the 2 Put the countershaft in a press so that race of the cone Remove and the main drive gear is toward the top of discard the cone Fi
113. ear is WASHER parallel to the reverse gear Make sure the snap rings are correctly installed Figure 14 27 Figure 14 27 35 Install the auxiliary drive gear assem bly on the mainshaft Make sure the bearing is installed toward the main shaft Figure 14 26 36 Install the snap ring that fastens the auxiliary drive gear to the mainshaft Figure 14 26 Page 148 Section 14 Overhauling the Mainshaft b Puta two feeler gauges between Three sizes of thrust washers are the hubs The clearance must be available 0 006 0 012 inch 0 152 mm For transmissions with serial num 0 304 mim Figure 14 28 bers LB93021753 the sizes are Figure 14 29 0 216 0 220 and 0 224 inch 5 50 5 60 and 5 70 mm For transmissions with serial num bers LB93021754 and above the sizes are 0 272 0 275 and 0 279 inch 6 90 7 00 and 7 10 mm e Remove the screwdrivers and feeler gauges 38 Remove the mainshaft assembly from 1 the vise rd tiny tty T eae E on the top of the mainshaft 0 152 0 304 MM idi t 39 Install the sliding collar over the roll pin 4 CAUTION Be careful when moving the mainshaft assembly The movement of the gears can damaged the washers c If the clearance is less than 0 006 inch 0 152 mm install a thinner selective washer in the reverse gear d If the clearance is more than 0 012 inch 0 304 mm install a thicker selective washer in the reverse g
114. ed mush roomed pieces can break and cause serious personal injury NOTE The Piloted Bearing Driver Tool must install the cup so that the cup extends at least 0 125 or 1 8 inch 3 mm above the surface of the case Make sure the Driver Tool does not touch the any part of the bearing cone or the cone will be damaged b Use a hammer and a Piloted Bearing Driver to install the rear cup in the bore The cup is cor rectly installed when the cup ex tends 0 125 or 1 8 inch 3 mm above the surface of the case Figure 12 69 Figure 12 69 DRIVER XXX 4 Pd 1 8 INCH c Clean three capscrews that fasten the countershaft rear bearing re tainer to the main case Apply Loctite 242 Meritor Part Number 2297 V 5430 or equivalent to the threads of the capscrews Section 12 Overhauling the Main Case CAUTION Use a new hardened countershaft bear ing retainer to install the rear counter shaft cup If a retainer that is not hard ened is used the transmissions will be damaged d Put a new hardened countershaft rear bearing retainer in position on the main case Install the cap screws Alternately and evenly tighten the capscrews to 35 Ib ft 47 N m until the retainer touches the main case Figure 12 70 GD Figure 12 70 TORQUE SEQUENCE WARNING Wear safe eye protection and make sure the tools are in safe condition If the tools are worn or damaged mush roomed pieces
115. ed for correct operation See the procedure of the manu facturer of the vehicle Lubricating the Remote Control Assembly Apply grease to the fittings on the linkage at the interval specified by the manufac turer of the vehicle Use the grease speci fied by the manufacturer of the vehicle Page 24 WARNING To prevent serious eye injury always wear safe eye protection when doing maintenance or service Removing the Shift Lever and Tower Assembly 1 Shift the transmission into the NEU TRAL position Remove the air from the air supply system 2 Disconnect the air lines from the shift knob at the slave valve 3 Remove the capscrews and the wash ers that fasten the shift tower housing to the top cover housing NOTE Do not lose any detent springs or balls when the shift tower housing is re moved If any springs or balls come out install the parts in the correct bore Install the ball before the spring is installed 4 Remove the shift tower housing and lever assembly and the gasket from the top cover housing Discard the gasket Figure 3 1 5 Remove any gasket material between the shift lever housing and the top cover housing Section 3 In Vehicle Service Figure 3 1 SHIFT LEVER AND TOWER ASSEMBLY Installing the Shift Lever and Tower Assembly 1 Make sure the transmission is in the NEUTRAL position Figure 3 2 Figure 3 2 NEUTRAL POSITION X 2 SEO AN
116. eeve and fork assem bly d Push the shaft through the assem bly until the holes in the fork and shaft are aligned Section 8 Standard Pattern Overhauling the Top Cover Assembly Top Cover f Install the lock wire in the holes in 11 Assemble the 1 2 shift rail assembly the capscrew and the fork and see the following procedure sleeve assembly Figure 8 21 9 Install the neutral check shaft in the NOTE i l bore on the top of the housing Make The 1 2 shift rail is the same size as the sure the round end of the shaft is 3 4 shift rail and has a hole drilled installed toward the low reverse shift through the rail shaft Make sure the end of the neu tral check shaft touches the slot in the NOTE Low Reverse shaft Figure Move the low reverse shift shaft assem 8 22 bly so that the interlock ball is com pletely installed in the bore Move the Figure 8 22 low reverse shaft assembly so that the NEUTRAL 1 2 rail can be installed CHECK a Put the 1 2 shift shaft in the middle bore of the housing Make sure the identification on the end of the shaft is toward the front of the housing Make sure the detent grooves in the shaft are aligned with the detent ball holes in the housing Figure 8 24 b Put the interlock pin in the hole drilled in the side of the 1 2 shift shaft Figure 8 24 Figure 8 24 10 Put the large interlock ball in the bot tom of the middle bore of the first set of bores on the rear of the
117. embly on the mainshaft Make sure the groove for the snap ring on the shaft is visible b Rotate the retainer so that the holes in the retainer are aligned with the bores in the case c Install and tighten the capscrews to 35 45 lb ft 47 61 Two Piece Retainer Figure 12 81 TWO PIECE a Install the bearing assembly in the RETAINER case over the mainshaft b Install the two piece retainer on the case c Install and tighten the capscrews to 35 45 lb ft 47 61 d Install the auxiliary drive gear on the mainshaft Make sure the groove for the snap ring on the shaft is visible 18 Install a new snap ring that fastens the auxiliary drive gear on the mainshaft Figure 12 80 Page 133 Section 13 Overhauling the Auxiliary Drive Gear Figure 13 1 WARNING To prevent serious eye injury always wear safe eye protection when doing maintenance or service Disassembling the Auxiliary Drive Gear Assembly 1 Remove the auxiliary case See Sec tion 11 Removing and Installing the Auxiliary Case 2 Remove the capscrews that fasten the bearing retainer of the auxiliary drive gear to the transmission case Figure 13 1 3 Remove and discard the snap ring that fastens the auxiliary drive gear to the mainshaft Figure 13 1 4 f a two piece retainer is used for the auxiliary drive gear use pry bars to separate the auxiliary drive gear from the mainshaft Remove the gear Hemove
118. er assembly See the following procedure a Remove the low synchronizer assembly from the LO gear as sembly Figure 16 61 Page 178 Figure 16 61 SYNCHRONIZER ASSEMBLY N LO GEAR AND HUB ASSEMBLY NOTE When separating the synchronizers put a towel over the synchronizers to keep the springs from flying out b Pull up on the high synchronizer to separate the high synchronizer from the low synchronizer Do not lose the springs when the synchro nizers are separated Figure 16 62 Figure 16 62 PULL UP 13 Speed Section 16 Transmission Overhauling the Auxiliary Case c Remove the springs from the holes Figure 16 65 SNAP RING in the high synchronizer Figure 16 63 Figure 16 63 SPRING 20 If necessary disassemble the splitter fork and shaft assembly d Remove the collar from the low 19016 596 synchronizer Figure 16 64 a Cut and discard the lock wire on the capscrew Remove the cap Figure 16 64 COLLAR diua p b Remove the splitter fork from the shaft Figure 16 66 CAPSCREW LOW SYNCHRONIZER e Remove the snap ring and washer that fastens the LO gear on the coupling Remove the thrust NS SPLITTER washer and the coupling FORK Figure 16 65 Page 179 Section 16 13 Speed Overhauling the Auxiliary Case Transmission 21 If worn or damaged remove the front and rear bearing cones and the splitter gear from the upper and lower auxiliary REAR counte
119. eral procedure to remove and install the remote control assembly 1 Raise the cab according to the proce dure of the manufacturer of the ve hicle 2 Measure the length of the adjusting rod from the centerline of each ball socket as shown in Figures 3 15 and 3 16 Mark the location of the adjusting rod and the ball sockets 3 Disconnect the linkage to the remote control assembly 4 Remove the capscrews that fasten the remote control housing to the top cover housing Remove the housing Re move and discard the gasket Remove any gasket material between the remote control housing and the top cover housing 5 Install a new gasket on the transmis sion 6 Put the remote control housing in position Install and tighten the cap screws to 35 45 lb ft 47 61 N m 7 Connect the linkage to the outer shift lever of the remote housing Install and tighten the nut to 12 18 lb ft 17 24 N m 8 Adjust the length of the adjusting rod to the distance measured in step 2 or to the distance specified by the manu facturer of the vehicle Figures 3 15 and 3 16 Section 3 In Vehicle Service To adjust the distance loosen the jam nuts and move the rod to the correct distance Tighten the jam nuts to 35 50 Ib ft 47 67 N m 8 Adjust the linkage according to the procedure of the manufacturer of the vehicle 9 Operate the vehicle and check for correct operation Figure 3 15 ONE PIECE ADJUST TO AD
120. ers one or two reverse switches may be used On 16 If necessary disassemble the low forward position top covers one re reverse sleeve and fork assembly verse switch Is used Remove the clip that fastens the plunger in the housing Remove the plunger and the spring Remove the spring and the ball from the bore next to the plunger bore Figure 8 15 14 Remove the reverse switch es or plugs from the top of the housing Remove the long pin s from each bore Figure 8 13 Page 58 Standard Pattern Section 8 Top Cover Overhauling the Top Cover Assembly Figure 8 15 PLUNGER Figure 8 16 BREATHER ND A SPRING N O If necessary remove the breather from i NEUTRAL the top of the cover Figure 8 16 SWITCH 18 Remove the neutral safety switch or BORE plug Remove the short pin from the bore Figure 8 17 19 Inspect all parts See Section 1 Repairing and Replacing the Parts Page 59 Section 8 Standard Pattern Overhauling the Top Cover Assembly Top Cover Assembling the Standard and Forward Position Top Cover Assembly See Figures 8 1 and 8 2 NOTE The standard position and the forward position top covers use different hous ing The forward housing also uses a plate and a gasket installed over the detent balls and springs 1 Lubricate all the parts of the top cover with the oil that is used in the transmis sion 2 Do the following to the set screws that
121. ershaft are a normal condi tion 15 Repeat steps 2 12 and check the end play of the other auxiliary countershaft 16 When the end play of 0 002 0 006 inch 0 050 0 152 mm is obtained do the following e On Nine Speed and Ten Speed Transmissions go to step 14 under Installing the Auxiliary Cover Nine Speed and Ten Speed Transmissions in Section 11 Removing and Installing the Auxil iary Cover e On Thirteen Speed Transmis sions go to step 14 under Install ing the Auxiliary Cover Thirteen opeed Transmissions in Section 11 Removing and Installing the Auxiliary Cover Page 206 General Information When checking a problem with the manual transmission the first thing to do is to make sure of the service condition Talk to the driver the mechanic or the service manager If possible take the vehicle for a road test There are three types of problems Leaks Noise and or vibration Operating conditions Oil Leaks Check the transmission for transmission oil leaks If you find oil on or under the transmission verify that the leak is transmission oil and not engine oil coolant or other lubricants Note that under normal conditions the area around the oil seal yoke and rear bearing retainer is moist This moist condition is not a transmission leak or an oil seal leak Refer to Section 3 Removing the Output Yoke and the Oil Seal for instructions on how to determine an oil s
122. esign Level 1 Transmissions when the end play is 0 002 0 006 inch 0 050 0 152 mm on each counter shaft repeat steps 1 5 on each coun tershaft to make sure the end play is correct If end play is correct return to step 13 in Section 12 Overhauling the Main Case If end play is not correct repeat the procedure in this section On Design Level 2 Transmissions when the end play is 0 002 0 006 inch 0 050 0 152 mm on each counter shaft do the following a Remove the Allen head capscrews that fasten the retainer to the main case b Apply Loctite 222 or equivalent to the threads of the capscrews c Install the capscrews Alternately and evenly tighten the capscrews to 120 140 Ib in 14 16 N m Figure 17 10 Figure 17 10 d Repeat steps 1 5 of this procedure to make sure the end play is cor rect e If end play is correct return to step 13 in Section 12 Overhauling the Main Case If end play is not correct repeat the procedure in this section Page 199 Section 18 Auxiliary Countershaft End Play Adjustment d WARNING To prevent serious eye injury always wear safe eye protection when doing maintenance or service Checking and Adjusting the End Play of the Auxiliary Countershaft NOTE Check the end play on one countershaft at a time 1 Install the auxiliary case on the main case as described in Section 11 Removing and Installing the Auxiliary Case 2
123. forward gears five gears in the LO range and eight gears in the HI range that are divided between four DIR gears and four O D gears and two reverse gears The transmission may be either a Design Level 1 or a Design Level 2 The auxiliary case is different from the nine speed and the ten speed transmissions Design Level 1 Manual Transmissions Design Level 1 Manual Transmissions apply to transmissions with serial numbers below LB93002000 The transmission is identified by the num ber 1 in the Design Level portion of the model number Figure 1 2 Section 1 General Information Figure 1 2 RMX10 145A2S002 Meritor Transmission Model Number O E M Transmission Manufacturing Date Part Number CUST MODEL SERIAL amp ASS Y PLANT RATIO Transmission Serial Number These Plugs Indicate Oil Pump RM X 10 145A 2 S 002 TYPE A Automated E Electric Air M Manual 5 Engine Synchro Shift SPEED W Shift by Progressive wis Forward HOUSING Speeds POSITION MERITOR F Foward S Standard SHIFT PATTERN No letter direct drive standard H pattern SPECIFICATION X overdrive DESIGN LEVEL Standard H pattern i oria Number O overdrive 9 speed LB93001999 and non standard pattern Below SHIFT BAR OR 2 Serial Numbers overdrive 13 speed LB93002000 and standard H pattern Above Page 7 Section 1 General Information Snap rings are used to retain the bearing
124. gure 15 2 the press Support the countershaft on the third or overdrive gear assembly Figure 15 2 Figure 15 4 3 Put a sleeve on the top of the shaft Press the shaft from the third or the overdrive gear the PTO gear and the main drive gear Figure 15 4 Figure 15 4 THIRD O imi OVEBDRIVE RT b Press Method Front Bearing Do steps 2 and 3 of this procedure UID c Press Method Rear Bearing Put a splitter tool under the race of dmm the cone Support the countershaft To on the splitter tool Put a sleeve Page 151 Section 15 Overhauling the Main Countershafts 4 Support the countershaft on the first or second gear Put a sleeve on top of the shaft Press the shaft from the second or the third gear and the first or the second gear Figure 15 5 Figure 15 5 FIRST OR SECOND 5 Remove the key from the groove in the shaft Figure 15 6 6 On Design Level 1 Transmissions remove the roll pin from the shaft Design Level 2 Transmissions do not use roll pin Figure 15 6 7 Inspect all parts See Inspecting the Parts in Section 1 Figure 15 6 Page 152 Assembling the Upper and the Lower Main Counter shaft Assemblies NOTE The upper and lower countershafts are each serviced in the same way NOTE See Figure 15 1 to identify the compo nents of the countershaft assembly for the transmission models 1 Lubricate all the parts with new oil that is used in
125. haft is removed from the transmission 1 If installed remove the 3rd 4th sliding collar from the mainshaft 2 Put the mainshaft in a vise with brass jaws Make sure the auxiliary drive gear end of the shaft is toward you 3 Remove the following parts of the mainshaft in this order Keep all parts together after disassembly NOTE See Figure 14 1 to identify the compo nents of the mainshaft assembly for the transmission models a Remove the snap ring from the second groove from the top of the shaft b Use a small punch to push the key away from the roll pin at the bottom of the shaft c Remove the key from the top of the shaft Page 138 d Remove the spacer and the thrust washer e Remove the reverse gear f Remove the clutch collar 0 Remove the thrust washer the spacer and the low or the first gear h Remove the first or the second gear i Remove the spacer and the thrust washer Remove the clutch collar k Remove the thrust washer the spacer and the second or the third gear m Remove the overdrive or the third gear n Remove the spacer and the thrust washer NOTE Remove the roll pin only if the pin is worn or damaged The roll pin is diffi cult to remove 4 f worn or damaged remove and replace the roll pin 5 If worn or damaged remove and replace the snap rings from inside the gears Figure 14 2 6 Inspect all parts See Inspecting the Parts in Section
126. he Breather Vent 22 Checking Fastener Torque 22 Inspecting the Transmission for Leaks and 22 Draining and Replacing the Transmission Oll cccceccccsseeeeeeeeeseeeeseeeeessaeeeseeseesees 23 Adjusting Remote Shift Housing Linkage 24 Lubricating the Remote Shift Housing ccccccceceececeeeeeseeeeeseeesaeeeesueeesseeeesaaeeesaees 24 Section In Vehicle 25 Removing the Shift Lever and Tower 5 25 Installing the Shift Lever and Tower 25 Removing the 27 installing th Slave MalUD 27 Removing the Air Filter and Regulator Assembly 28 Installing the Air Filter and Regulator Assembly 29 Removing the Output Yoke and Oil 5 29 Installing the Oil Seal and Output YOKE 30 Removing and Installing the Remote Control 33 Table of Contents Continued SUBJECT PAGE Sec
127. he bores for the retainers are aligned b If clips are used install a bushing in each side Install a clip on one end of the pin Install the pin in the bores Install the clip on the other end of the pin c Ifa bolt and nut is used install the bolt in the bores Install and tighten the nut to 8 12 lb ft 11 16 N m 47 Section 6 Overhauling the Remote Control Assembly AX WARNING To prevent serious eye injury al ways wear safe eye protection when doing maintenance or service Disassembling the Remote Control Assembly 3 Remove the lockwire and the set Refer to Figure 6 1 screw that fasten the inner shift lever to the shaft Remove the shaft and the 1 Remove the set screw that fastens the inner shift lever outer shift lever to the shaft Remove the lever 4 Inspect the bushings in the housing If worn or damaged use a driver tool to 2 Remove and discard the two tie straps remove the bushings that fasten the boot to the housing Remove the boot 5 If necessary loosen the sockets and remove the adjusting rod Figure 6 1 cL ome N LOCK SET 5 WIRE SCREW D ADJUSTING ROD ONE PIECE SHOWN SOCKET Page 48 Section 6 Overhauling the Remote Control Assembly Assembling the Remote Control Assembly 1 Do the following to the set screws that fasten the levers to the shaft a Clean the threads of the set screws with Loctitie amp Safety Solvent
128. he following procedure Figure 8 51 a Install the guide pin through the rocking lever b Install the spacer plate on the guide pin A Install the O ring on the guide pin after installing the rocking lever and the spacer plate or the O ring will be damaged c Install a new O ring on the guide pin d Install the assembly so that the long part of the spacer plate is toward the center of the housing X Bar Top Cover e Install a new nut and a new washer that fasten the guide pin to the housing Tighten to 35 45 Ib ft 47 54 N m WASHER Figure 8 51 GyipE o RING SPACER PIN ROCKING LEVER 5 Install the low reverse fork assembly according to the following procedure Figure 8 52 a Put the low reverse shift shaft in the bottom bore in the rear of the housing Make sure the two detent grooves are toward the rear of the housing Make sure the detent grooves in the shaft are aligned with the detent ball holes in the housing Put the low reverse shift fork assembly in the housing so that the lower lever slot is toward the center of the assembly Make sure the bore of the fork is aligned with the bore in the housing Push the shift shaft through the fork and sleeve assembly until the holes in the fork and shaft are aligned Section 8 Overhauling the Top Cover Assembly AX CAUTION After the set screws with the Loctite sealant see step 2 are tightened to
129. he procedure for if the reading the reading is 0 012 0 014 inch is 0 020 inch or more 0 280 0 355 mm see the following a Remove the Allen head capscrews and remove the retainer b Remove the 0 0075 inch 0 190 mm shim Meritor part number 2803 5 2827 196 Section 17 Main Countershaft End Play Adjustment Install the retainer Instal the Allen head capscrews Alternately and evenly tighten the capscrews to 120 140 Ib in 14 16 Check the end play as described in steps 1 5 of this procedure 12 On Design Level 2 Transmissions if the reading is 0 015 0 019 inch 0 356 0 482 mm see the following 13 a Hemove the Allen head capscrews and remove the retainer Remove the 0 005 inch 0 127 mm shim Meritor part number 2803 R 2826 Remove the 0 0075 inch 0 190 mm shim Meritor part number 2803 5 2827 Install the retainer Instal the Allen head capscrews Alternately and evenly tighten the capscrews to 120 140 Ib in 14 16 N m o Check the end play as described in steps 1 5 of this procedure On Design Level 2 Transmissions if the reading is 0 020 inch 0 483 mm or more see the following a Hemove the Allen head capscrews and remove the retainer Remove and discard all the shims including the original shims NOTE Shim KIT 5364 uses the following shims 0 Two 0 0050 inch 0 127 mm shims 0 Two 0 0075 inch 0 190 mm shims One 0 0175 i
130. hes the shoulder on the shaft Figure 15 11 PRESS ONLY Nine Speed and Ten Speed Section 16 Transmissions Overhauling the Auxiliary Case Disassembling the Auxiliary Case Nine and Ten Speed Transmissions See Figure 16 1 Figure 16 1 92 SEAL j OUTPUT cn BEARING AND as ASSEMBLY OS 2 AIR j ef FILTER REGULATOR 9 ASSEMBLY RANGE CYLINDER ASSEMBLY S d N COUNTERSHAFT AUXILIARY COVER COUNTERSHAFT AUXILIARY ASSEMBLY CASE HI LO FORK in OUTPUT SHAFT ASSEMBLY SYNCHRONIZER ASSEMBLY DESIGN LEVEL 1 DESIGN LEVEL 2 Page 155 Section 16 Nine Speed and Ten Speed Overhauling the Auxiliary Case Transmissions d WARNING To prevent serious eye injury always Figure 16 3 wear safe eye protection when doing PISTON maintenance or service 1 If necessary remove the air filter regulator assembly from the range cylinder cover 2 Remove the capscrews and washers from the range cylinder cover Re move the range cylinder cover Figure 16 2 Figure 16 2 RANGE CYLINDER AX WARNING If necessary use a safe amount of air pressure at the LO range port to remove the piston from the range cylinder If too much air pressure is used the piston will come out of the housing with enough force to cause serious personal injury 5 Remove the piston from the bore of the range cylinder Inspect the large O ring on the outer diameter of the pis
131. hined surface of the case If the surface is damaged the case will leak 7 Put the top cover assembly on the bench so that the forks are toward you or in a vice with brass protectors on the jaws of the vise Page 68 Bar Section 8 Top Cover Overhauling the Top Cover Assembly 8 Remove the capscrews that fasten the 10 Remove the set screw from the 3rd 4th large and the small oil scoops to the fork and the 3rd 4th shift fork shaft cover Figure 8 38 from the housing Remove the 3rd 4th fork Figure 8 40 Figure 8 38 LARGE OIL Figure 8 40 3 4 SHIFT FORK SMALL OIL SCOOP 9 Remove the lock wire from the follow ing Figure 8 39 11 Remove the set screw and remove the 3 4 shift sleeve shaft from the housing 3rd 4th fork Remove the 3 4 X bar sleeve 3rd 4th shift sleeve Figure 8 41 1st 2nd shift fork 1st 2nd shift sleeve LOW Reverse shift fork Figure 8 39 3 4 X BAR SLEEVE 12 Remove the interlock ball from the bottom of the top bore of the first set of bores at the rear of the housing Figure 8 42 Page 69 Section 8 X Bar Overhauling the Top Cover Assembly Top Cover Figure 8 42 Figure 8 44 1 2 SHIFT 1 2SHIFT SLEEVE 4 9 SHIFT SHAFT ae d NE 13 Remove the interlock pin from the end 15 Remove the interlock ball from the of the 1 2 shift shaft Figure 8 43 bottom of the middle bore in the first set of bores in the rear of the housing F
132. hrough the inside of the case c Usea rubber mallet to tap the input shaft assembly in position The input shaft assembly is correctly installed when there is a slight clearance between the main drive gear and the transmission case Figure 12 43 Figure 12 43 d Install the snap ring in the groove on the input shaft bearing Figure 12 44 4 On Design Level 2 Transmissions install the input shaft See the follow ing procedure a Lubricate all parts with new oil that is used in the transmission b If removed install the snap ring inside the main drive gear c Install the main drive gear in posi tion in the case Figure 12 45 Page 120 Figure 12 44 d If removed install a new bushing in the end of the input shaft Use a hammer and the correct driver to install the bushing Install the input shaft through the main drive gear The shaft is correctly installed when the groove for the snap ring on the shaft is towards the outside the case Figure 12 46 Section 12 Overhauling the Main Case Figure 12 46 Figure 12 48 BEARING Sa SNAP RING f Install the spacer on the input shaft CAUTION Figure 12 47 Put the tube on the inner race of the bearing If tools are used in any other 12 47 Figure place on the bearing the bearing will SPAG be damaged i Put the bearing over the input shaft and in the case Use a rubber or plastic mallet and G a
133. ied torque 2 Loose fasteners Tighten to specified torque 3 High oil level Drain to specified level See overheating in Operating Conditions Unspecified oil in transmission Drain oil Install specified oil Clogged or dirty breather vent Clean breather vent Damaged yoke Replace yoke Damaged output shaft seal Replace output shaft seal Worn or damaged sealing tape on Install new sealing tape on electronic electronic speed sensor speed sensor Leaks Remove Damaged gaskets or sealing Replace gaskets or sealing material and Disassemble material Transmission Cracked or broken housing Replace housing Oil leaking from breather vent 2 Replace O ring in piston housing NOTES Ifthe transmission continues to leak and the output shaft seal and the yoke have been replaced remove and replace the output shaft assembly Put the transmission in the LO range and operate the vehicle If air leaks from the breather vent the O ring in the housing of the range cylinder is damaged Troubleshooting Vibrations Before troubleshooting a vibration condition make sure of the following 1 The engine idle speed is within the specified range 2 The engine is operating correctly 3 The U joints yokes and driveshaft are in good condition Check the driveline angles Correct as neces Sary 4 The U joints the yokes and the driveshafts are correctly aligned and or balanced Correct as necessary
134. igure 4 9 the body is worn or damaged replace the clutch brake Inspect the lining material on the clutch brake Replace the clutch brake if the lining is worn or damaged Figure 4 9 If removed install the clutch brake on the input shaft of the transmission Make sure the large part of the brake is toward the input bearing retainer and the tabs on the brake engage the slots in the input shaft Figure 4 9 CLUTCH Section 4 Removing and Installing the Transmission 12 Put the transmission in gear A WARNING Make sure the transmission is securely supported on the overhead hoist or jack If the transmission is not securely supported the transmission may fall and cause serious personal injury or damage 13 Put the transmission on a transmission jack or an overhead hoist 14 If installed remove the inspection cover from the clutch housing A CAUTION Be careful when installing the input shaft of the transmission in the hubs of the disc If the transmission is forced or jammed the clutch discs or the clutch housing will be damaged Also do not let the transmission hang or be Figure 4 10 SEE VIEW A e Yy NENNEN quo o WES ZZ rj INPUT SHAFT MUST BE ALIGNED WITH PILOT BEARING Page 38 supported by the clutch or the discs The clutch or the discs are damaged when the transmission is not correctly installed 15 Install the transmission according to the following pro
135. igure 8 29 Figure 8 29 3 4 SLEEVE Standard Pattern Top Cover b Put the 3 4 shift sleeve in the housing Make sure the bore of the fork and sleeve assembly is aligned with the bore in the housing Make sure the slot pin in the 3 4 sleeve is aligned with the hole in the 1 2 sleeve Figure 8 30 Figure 8 30 C e Push the shift shaft through the 3 4 shift sleeve Put the 3 4 shift fork in the housing Make sure the bend on the fork is installed toward the last set of bores in the housing Make sure the bore of the fork is aligned with the bore in the housing Figure 8 29 Push the shift shaft through the 3 4 fork Push the shaft through the assem bly until the holes in the fork and the sleeve are aligned with the holes in the shaft Section 8 Overhauling the Top Cover Assembly 4 After the set screws with the Loctite sealant see step 2 are tightened to the specified torque do not loosen or tighten If loosened or tightened the set screws must be removed cleaned and new sealant applied or the set screws may loosen during operation h Install the set screws with the Loctite sealant see step 2 that fastens the 3 4 fork and the sleeve to the rail Tighten the set screw to 35 45 lb ft 47 54 i Install the lock wire in the cap screws the sleeve and the fork 15 If removed install the large oil scoop on the housing Install and tighten the capscre
136. igure 8 43 Figure 8 45 Figure 8 45 BALL 14 Remove the set screws and remove the 1 2 shift shaft the 1 2 shift fork and the 1 2 shift sleeve from the housing Figure 8 44 Page 70 Bar Section 8 Top Cover Overhauling the Top Cover Assembly CAUTION Remove the O ring on the guide pin Figure 8 47 before removing the rocking lever and NEUTRAL the spacer plate or the O ring will be damaged 16 Remove the nut and the washer that fasten the guide pin and the rocking lever assembly to the housing Re move the O ring from the guide pin Remove the rocking lever and the spacer plate Figure 8 46 Inspect the O ring on the guide pin Replace the O ring if worn or damaged Figure 8 46 SPACER i O RING LOW REVERSE WASHER SHIFT SHAFT ROCKING LEVER LOW REVERSE SHIFT FORK 17 Remove the neutral check shaft from the top cover assembly Figure 8 47 PLUNGER AND 18 Remove set screws and remove the SPRING low reverse shift shaft Remove the low reverse shift sleeve and fork as sembly Figure 8 48 19 If necessary disassemble the low reverse sleeve and fork assembly Remove the clip that fastens the plunger in the housing Remove the plunger and the spring Remove the spring and the ball from the bore next to the plunger bore Figure 8 49 20 Inspect all parts See Section 1 Re pairing or Replacing the Parts Page 71 Section 8 Overhauling the Top Cover Assembly
137. inch 0 152 mm install a thinner selective washer If the clearance is more than 0 012 inch 0 304 mm install a thicker selective washer Three sizes of thrust washers are available For transmissions with serial num bers LB93021753 the sizes are 0 216 0 220 and 0 224 inch 5 50 5 60 and 5 70 mm For transmissions with serial num bers LB93021754 and above the sizes are 0 272 0 275 and 0 279 inch 6 90 7 00 and 7 10 mm e Remove the screwdrivers and feeler gauges 2 Install the sliding collar on the shaft Make sure the slot in the collar is installed over the key Figure 14 19 Figure 14 19 RE SLIDING COLLAR SLOT FOR KEY Page 146 AX CAUTION Use the correct selective washer Do not mix washers or the transmission will not operate correctly 28 Choose the correct selective thrust washer for the reverse gear See the following e Ifthe selective washers are not replaced use the original washers e If the selective washers are re placed install the medium size of washer For transmissions with serial num bers LB93021753 and below use a 0 220 inch 5 60 mm washer For transmissions with serial num bers LB93021754 and above use a 0 275 inch 7 00 mm washer 29 Remove the key Install the selective thrust washer for the reverse gear See the following Figure 14 20 a Install the washer on the shaft Make sure the smooth side Is towards you
138. ing 25 Removing 25 Index shim KIT 5376 Chart 197 shuttle Valve Installing 191 Removing 174 Slave Valve Installing 27 Removing 27 Snap Ring Chart 194 Special Tools 230 Splitter Fork Assembling 183 184 Disassembling 178 Installing 186 187 Removing 177 Synchronizer Assembling 167 184 Disassembling 159 177 Installing 168 187 Removing 159 176 Timing 9 Top Cover Assembling Standard 60 Assembling X Bar 72 Disassembling Standard 54 Disassembling X Bar 66 Identification 50 Installing 52 Removing 50 Torque 22 215 224 Transmission Installing 36 Removing 34 Yoke Installing 30 Removing 29 Page 233 ZF Meritor LLC 22021 Skyway Church Road Maxton NC 28364 USA 800 535 5560 Www arvinmeritorinc com fi3iwERrroR Information contained in this publication was in effect at the time the publication was approved for printing and is subject to change without notice or liability ZF Meritor LLC reserves the right to revise the information presented or discontinue the production of parts described at any time Copyright 2000 Maintenance Manual 26A ZF Meritor LLC Revised 12 98 All Rights Reserved Printed in the USA 16579 24240
139. ing Cover Template 3305 W 1141 4 5 0 11 INCH 114 30 3 00 mm 1 25 INCH 1 62 INCH 4 6200mm 00 mm 41 15 mm B dii bog 1 1 0 INCH 1 11 mm 0 075 INCH DIAMETER 9 53 mm 2 25 INCH 57 15 mm 0 25 INCH gt 6 35 mm Page 229 Section 20 Specifications Special Tools Tool Description Tool Number Tool Manufacturer Bearing Puller Tool 3256 W 1037 Meritor 41086 Kent Moore o Bearing Cup Seating Tool 3256 T 1034 Bearing Service Set OTC 7070 Owatonna Input Shaft Removal Pusher Tool G 28 G amp W Checking Tool 41335 Kent Moore Oo Tool D 2 Holding Cover Plate 3305 W 1141 Input Shaft Bearing G 38 G amp W Remover nput Shaft installe Light Duty Puller Set Seal Driver Seal Driver D Spacer Washer 1229 N 4538 T Handle Too 3256 Y 1013 NOTES Meritor tools are available wherever Meritor parts are sold Order Kent Moore Tools from Kent Moore Heavy Duty Division 29874 Little Mack Roseville MI 48066 2298 Order Owatonna Tools from OTC Tool and Equipment Division 655 Eisenhower Drive Owatonna MN 55060 2 Contact your local Snap On tool distributor Order G amp W Tools from G amp W Tool Company 1105 E Louisville Broken Arrow OK 74012 Input Shaft Bearing G 35 G amp W Driver Page 230 Index Air Filter and Regulator Assembly Installing 29 Removing 28 Air Line Identification 9 10 Speed 226 Identificat
140. ings Hissing only 1 Replace bearings Thumping or 2 Damaged gear teeth Thumping or 2 Replace gears Bumping 2 bumping only Rattles 1 Engine idle speed not within 1 Adjust idle speed to specified RPM In Vehicle specifications Repair 2 Engine does not operate on all Adjust or repair engine cylinders 3 Clutch intermediate or center Repair or replace intermediate plate binding in housing 9 or center plate 4 Other systems Make sure the transmission is the source of the rattle condition 5 Incorrect shim installation on the Install correct shims on PTO unit PTO unit Rattles 1 Damaged washers between Replace washers between Remove and mainshaft gears mainshaft gears Disassemble Transmission Squealing or 1 Incorrect shim installation on 1 Install correct shims on PTO unit Whining In PTO unit Vehicle Repair Squealing or 1 Damaged bearings 1 Replace bearings Whining 2 End play of countershafts not 2 Adjust countershaft end play Remove and within specifications withing specifications Disassemble Transmission NOTES Growling and humming are associated with the first stages of the condition Grinding is associated with the severe stages of the condition is associated with the first stages of the condition Thumping and bumping are associated with the severe stages of the condition amp Ifthe noise occurs when the clutch is engaged and stops when the clutch is d
141. ion 13 Speed 228 Location 9 10 Speed 225 Location 13 Speed 227 Auxiliary Case Assembling 9 10 Speed 163 Assembling 13 Speed 181 Disassembling 9 10 Speed 155 Disassembling 13 Speed 173 Installing 9 10 Speed 90 Installing 13 Speed 98 Removing 9 10 Speed 85 Removing 13 Speed 94 Auxiliary Countershaft Assembling 9 10 Speed 166 Assembling 13 Speed 185 Disassembling 9 10 Speed 160 Disassembling 13 Speed 179 End Play 199 205 Installing 9 10 Speed 166 Installing 13 Speed 186 Removing 9 10 Speed 159 Removing 13 Speed 177 Timing 9 10 Speed 163 Timing 13 Speed 183 Auxiliary Drive Gear Assembling 136 Disassembling 134 Installing 103 Removing 102 Auxiliary Low Gear Timing Mark 163 Bearing Cone and Cup Inspecting 15 18 Replacement Chart 15 Bearing Cone Auxiliary Countershaft Installing 9 10 Speed 166 Installing 13 Speed 185 Removing 9 10 Speed 160 Removing 13 Speed 179 Bearing Cone Main Countershaft Front Lower Installing Removing Bearing Cone Main Countershaft Front Upper Installing 126 129 Removing 106 107 Bearing Cone Main Countershaft Rear Lower Installing Removing Bearing Cone Main Countershaft Rear Upper Installing 154 Removing 151 Bearing Cup Auxiliary Countershaft Front Installing 9 10 Speed 90 172 Installing 13 Speed 191 Removing 9 10 Speed 89 Removing 13 Speed 9
142. irst set of bores at the rear of the housing Figure 8 26 Figure 8 26 13 Make sure the low reverse sleeve and the 1 2 sleeve are in the NEUTRAL position The slots in the sleeve must be aligned Figure 8 27 Page 63 Section 8 Overhauling the Top Cover Assembly Figure 8 27 SLEEVES IN NEUTRAL POSITION o E o E we Je 14 If removed install the plunger assem bly in the 3 4 shift sleeve Put the sleeve in a vise with brass jaws Install the spring if used and the plunger in the sleeve Install the snap ring that holds the assembly in the fork Figure 8 28 Figure 8 28 PLUNGER AND SPRING RS _ 64 Standard Pattern Top Cover NOTE On R ratio transmissions the bill of material refers to the 3 4 shift fork as the O D Overdrive shift fork and the 3 4 shift sleeve as the O D shift sleeve 15 Assemble the 3 4 shift rail assembly See the following procedure NOTE The 3 4 shift shaft has a slot on one side NOTE Move the 1 2 shift shaft assembly so that the interlock ball is completely installed in the bore Move the 1 2 shaft assembly so that the 3 4 shaft can be installed a Put the 3 4 shift shaft in the top bore of the housing Make sure the interlock slot on the end of the rail is toward the rear of the housing Make sure the detent grooves in the shaft are aligned with the detent ball holes in the housing F
143. isengaged the the interme diate or center plate is the cause of the rattle Whining is a medium pitched noise Squealing is a high pitched noise Page 210 Section 19 Troubleshooting Troubleshooting Operating Conditions CONDITION CAUSE REPAIR Transmission Slips Out of the Selected Range In Vehicle Repair Transmission Slips Out of the Selected Range Remove and Disassemble Transmission Transmission is Slow to Shift or Unable to Shift into the Selected Range In Vehi cle Repair Transmission is Slow to Shift or Unable to Shift into the Selected Range Remove and Disassemble Transmission NOTES 1 Loose air lines and fitings 2 Obstructions in air lines 3 6 7 Check operation of filter regu lator assembly Damaged O ring on piston in range shift cylinder Loose or missing nut that fastens piston to shift shaft in range shift cylinder Worn teeth in sliding clutch Bent or worn shift fork Worn collar on range shift fork Loose or leaking air lines and fittings Obstructions in the air lines Filter regulator assembly does not operate correctly Spool binding in slave valve Leakage at slave valve Damaged piston and or O rings in piston housing Worn or damaged neutral interlock pin Damaged shift knob selector valve Damaged exhaust disc in slave valve Damaged output shaft Broken or missing synchro
144. ition Page 101 Section 11 Removing and Installing the All Auxiliary Case Transmissions Removing the Auxiliary Figure 11 39 Drive Gear 1 Remove and discard the snap ring that fastens the auxiliary drive gear to the mainshaft Figure 11 38 2 Use pry bars to separate the auxiliary drive gear from the mainshaft Re move the gear Figure 11 39 3 Remove and discard the two O rings from the gear Figure 11 40 Figure 11 38 pd i 9 SNAP RING Page 102 Section 11 All Removing and Installing Transmissions the Auxiliary Case Installing the Auxiliary Figure 11 41 Drive Gear 1 Lubricate all parts with new oil that is used in the transmission 2 Lubricate new O rings with new oil that is used in the transmission Install new O rings on the gear 3 Install the auxiliary drive gear assem bly on the mainshaft and in the rear of the case Figure 11 41 4 Install a new snap ring that fastens the auxiliary drive gear on the mainshaft Figure 11 42 9 SNAP RING Page 103 Section 12 Overhauling the Main Case Figure 12 2 d WARNING To prevent serious eye injury always wear safe eye protection when doing maintenance or service Removing the Mainshaft NOTE If the auxiliary drive gear is removed go to step 5 1 Remove the capscrews that fasten the bearing retainer of the auxiliary drive gear to the transmission case AUXILIARY DRIVE GEAR Figure 12
145. l is even with the bottom of the hole of the fill plug Figure 4 11 Page 39 Section 4 Removing and Installing the Transmission see Transmission Oil Capacities and Figure 4 11 Transmission Oil Specifications in Section 20 Specifications ees a Fe n Install and tighten the fill plug to 35 50 p PLUG lb ft 48 67 N m 29 Operate the vehicle Check for correct operation Page 40 Section 5 Overhauling the Shift Lever and Tower Assembly AX WARNING To prevent serious eye injury always wear safe eye protection when doing main tenance or service Disassembling the Aluminum Shift Lever and Tower Assembly See Figure 5 1 Figure 5 1 CLAMP e SE SNAP UPPER RETAINER PLATE LOWER RETAINER PLATE SPRING ain e SET SCREW Page 41 Section 5 Overhauling the Shift Lever and Tower Assembly NOTE If an aluminum shift tower assembly is replaced replace the entire assembly With a cast iron shift tower assembly Make sure the gasket between the shift tower housing and the top cover hous ing is replaced A different gasket is used on the aluminum than on the cast iron housing 1 Remove the shift lever and tower assembly as described in Section 3 In Vehicle Service 2 f necessary separate the upper shift lever from the lower shift lever See the following a If clips are used remove one clip Remov
146. l the correct selective snap rings that fas tens the cups in the cover Make sure the snap ring is completely installed in the groove Figure 16 95 On Design Level 2 Transmissions install the cups on the cones of the auxiliary countershafts Install the correct selective washers in front of the cups Make sure the tabs in the wash ers are in the slots in the case Page 188 13 Speed Section 16 Transmission Overhauling the Auxiliary Case 18 Put the holding plates on both auxiliary 20 Put the HI LO shift fork in position so countershafts Use capscrews to that the fork engages the synchronizer fasten the plates to the countershaft collar Make sure the bore of the fork and the cover DO NOT CHANGE is aligned with the bore of the piston THE POSITION OF THE housing Make sure the lock pin hole TRANSMISSION IN THE REPAIR in the fork is installed away from the STAND Figure 16 96 cover Figure 16 98 Figure 16 96 21 Install the HI LO shift shaft from the inside the front of the auxiliary cover Make sure the threads on the end of the shaft are installed first Rotate the shaft while pushing the shaft through the O ring Figure 16 98 NOTE If a pin and a clip was used to fasten the HI LO fork to the shaft replace the pin and the clip with a nut NL 25 1 and shoulder bolt 10 X 1534 22 Align the hole of the shaft with the hole of the shift fork Install the bolt and the lock nut Tighten the nut to 8 12 Ib ft 19
147. lace any worn or damaged bearings Gears Inspect the teeth of the gears for wear and damage Inspect the splines inside the gears for wear and damage Inspect the gears for cracks or pits Replace gears that are worn damaged or cracked Shafts Inspect the splines and the grooves for wear and damage Make sure the shafts are not twisted Make sure threads on the end of the shafts are not worn or damaged Replace any worn or damaged shafts Page 18 O Rings and Oil Seals Inspect the O rings and the oil seals for cuts and cracks Make sure the parts are not brittle or hard Replace any worn damaged or hard O rings and oil seals Clutch Collars Inspect the teeth of the outside of the clutch collar for wear and damage Inspect the splines inside the clutch collar for wear and damage Replace any worn or dam aged clutch collars Case Housings Inspect the case housings for cracks Replace cracked housings Top Cover Inspect the tips of the forks for wear and damage Make sure the forks are not bent Make sure the shift rails are not worn or damaged Inspect the balls and springs for wear or damage Replace any worn or damaged parts Output Yokes Inspect the seal surface the splines and the end of the output yoke for wear and damage Do not sand or grind the seal surface Replace any worn or damaged parts Repairing or Replacing the Parts Replace worn or damaged parts The following are some examp
148. les to check 1 Replace any fastener if the corners of the head are worn 2 Replace the washers if damaged 3 Replace gaskets and oil seals at the time of transmission repair 4 Clean the parts and apply new gasket material where required when the transmission is assembled See Gas ket Sealant in this section 5 Remove nicks mars and burrs from parts having machined or ground surfaces Use fine file india stone or crocus cloth for this purpose except for yokes 6 Clean and repair the threads of fasten ers and holes Use adie or tap of the correct size or a fine file for this pur pose Aa caution Threads must be clean and undamaged so that accurate adjustments and cor rect torque values can be applied to fasteners and parts 7 Use the correct type of Loctite or equivalent and tighten all fasteners to the correct torque values See the Torque Chart in Section 20 Specifica tions Cleaning the Ground or Polished Parts A WARNING If you use cleaning solvents hot solu tion tanks or alkaline solutions incor rectly injury can occur To prevent Section 1 General Information injury follow the instructions supplied by the manufacturer Do NOT use gaso line to clean parts Gasoline can ex plode Use a cleaning solvent to clean ground or polished parts and surfaces Kerosene or diesel fuel can be used for this purpose DO NOT USE GASOLINE Do clean ground or polished
149. ll in the bore next to the plunger c Install the plunger and the spring in the bore of the fork d Install the snap ring that holds the assembly in the fork Standard Pattern Section 8 Top Cover Overhauling the Top Cover Assembly Figure 8 19 PLUNGER Figure 8 20 AND SPRING 8 Assemble the low reverse shift shaft assembly See the following proce Aa caution dure After the setscrews with the Loctite sealant see step 2 are tightened to the NOTE specified torque do not loosen or The low reverse shaft is the shortest of tighten If loosened or tightened the the three shafts set screws must be removed cleaned and new sealant applied or the set a Put the low reverse shift shaft in screws may loosen during operation the bottom bore of the housing Make sure the boss on the end of the shaft is toward the rear of the housing Make sure the detent grooves in the rail are aligned with the detent ball holes in the housing e Install the set screw with the Loc tite sealant see step 2 that fasten the fork in position on the shaft Tighten the set screw to 35 45 lb ft 47 54 Figure 8 21 Figure 8 20 b Put the low reverse shift fork as Figure 8 21 sembly in the top cover so that the SET SCREW plunger of the fork is toward you Make sure the bore of the fork and sleeve assembly is aligned with the bore in the housing Figure 8 20 c Push the shift shaft through the low reverse sl
150. lling lockwire do the following a rim excess wire to a 1 4 inch 6 mm length b Bend the wire towards the capscrew C Twist the wire at least once between parts d On the 1 2 sleeve the wire can be wrapped around the shaft nottighten more than the specified torque or the output bearing may be damaged Page 224 Section 20 Specifications Air Line Locations Nine Speed and Ten Speed Transmissions MAIN VIEW r 3 YELLOW AF ir oe 2 RED 4 RED Bag ls 1 BLACK i FILTER REGULATOR ASSEMBLY AND RANGE CYLINDER 5 BLACK PABEUE 4 RED Page 225 Section 20 Specifications Air Line Identification C hart Nine Speed and Ten Speed Transmissions Hose Hose Outer Description Color Diameter Specification 1 Pilot Fitting on Selector Valve to Pilot Black 5 32 inch SAE J 844 Fitting on Slave Valve or 1 8 inch Pilot Supply Fitting on Selector Valve to Red 5 32 inch SAE 844 Pilot Supply Fitting on Slave Valve or 1 8 inch Exhaust Fitting on Selector Valve Y ellow 5 32 inch SAE J 844 TypeA Supply Fitting on Filter Regulator to 5 16 inch SAE J 844 Supply Fitting on Slave Valve A 5 LO Range Port on Slave Valve to Black 5 16 inch SAE J 844 LO Range Port on Range Cylinder Range Port on Slave Valve to Blue 5 16 inch SAE J 844 HI Range Port on Range Cylinder A NOTES
151. lowing procedure Figure 16 29 d Put the outer cup on top of the inner cup Make sure the slots of CAUTION the outer cup are against the inner A bearing heater can be used to install cup Figure 16 27 the bearing cone Follow the instruc tions of the manufacturer of the bearing Figure 16 27 heater The heated cones can burn you a Put the countershaft in a press so that the front of the countershaft is toward the top of the press Sup port the countershaft on the gear b Put the front cone on the counter shaft so that the bottom of the cone is toward the gear c Puta sleeve on the inner race of the cone Press the cone on the countershaft The cone is correctly installed when the bottom of the cone touches the gear d Turn the shaft over so that the opposite end is toward the top of the press Repeat steps a c to install the rear cone e Puta sleeve or installation tool on the top of the outer cup Press both cups into the bore The cups are correctly installed when the outer cup touches the shoulder in the bore of the cover Figure 16 28 Page 166 Nine Speed and Ten Speed Section 16 Transmissions Overhauling the Auxiliary Case Figure 16 29 c Put the auxiliary cover on the output shaft and low gear assembly and the auxiliary countershafts Figure 16 31 Figure 16 31 c A IF e mmm o TY f
152. ly 1 Use an air gun to apply air pressure to the LO range port in the piston housing to put the case in the LO range 2 On Design Level 1 Transmissions if removed install the snap rings in the bores for the cups for the auxiliary countershafts in the main case Fig ure 11 29 Page 98 Section 11 Thirteen Speed Removing and Installing Transmission the Auxiliary Case Figure 11 31 AUXILIARY COVER TO TRANSMISSION CASE GASKET PATTERN PUT THE PATTERN ON THE TRANSMISSION CASE AND THE AUXILIARY COVER TRANSMISSION CASE GASKET PATTERN AUXILIARY COVER GASKET PATTERN BOLT HOLE TRANSMISSION CASE APPLY SEALANT BOLT HOLE IN A 1 8 INCH 2MM BEAD 4 Use a sealant dispenser and Loctite RTV Sealant 5699 Meritor Part Figure 11 32 Number 2297 A 7021 to put a new sealant pattern for the auxiliary case on the transmission case a 1 8 inch 3 2 5 INCHES mm bead in the pattern shown in 64 mm Figure 11 31 Put a sealant pattern around each puller hole in the auxiliary case as shown in Figure 11 31 See Gasket Sealant in Section 1 A WARNING When using a hammer and a steel drift wear safe eye protection and make sure the tools are in safe condition Do not use tools that are worn or damaged mushroomed If the tools are not in 6 Lubricate the dowel pins with new oil safe condition pieces can break and that is used in the transmission cause serious personal injury a 7 Connec
153. mp W Tool G 35 Input Shaft Bearing Driver to install the bearing on the input shaft The bearing is correctly installed when the snap ring touches the case Figure 12 49 Figure 12 49 INPUT SHAFT BEARING DRIVER g If removed install the outer snap ring on the bearing h Install the bearing over the shaft and in the case Figure 12 48 Page 121 Section 12 Overhauling the Main Case j Install the snap ring in the groove Figure 12 51 on the input shaft bearing 9 INPUT BEARING RETAINER TO TRANSMISSION Figure 12 50 CASE GASKET PATTERN Figure 12 50 PUT THE PATTERN ON THE INPUT BEARING RETAINER BEAD TO BE KEPT OUTSIDE RETAINER SNAP RING NOTE APPLY SEALANT IN A 1 8 INCH Figure 12 52 INPUT BEARING RETAINER 5 Use a sealant dispenser and Loctite RTV Sealant 5699 Meritor Part Number 2297 A 7021 to put a new sealant pattern on the case for the retainer in the pattern shown in Figure 12 51 See Gasket Sealant In Section 1 6 Put the input bearing retainer on the case Install the mounting capscrews and washers Tighten the capscrews to 25 35 lb ft 34 47 Figure 12 52 o Page 122 Section 12 Overhauling the Main Case Installing the Main Figure 12 54 Countershafts MARK ONE TOOTH NOTE The bearing cup and the bearing cone must be replaced as an assembly Do not replace the cup or the cone sepa rately Replace the cup and the c
154. n Speed Overhauling the Auxiliary Case Transmissions b Remove the springs from the holes Figure 16 15 in the high synchronizer Figure 16 13 Figure 16 13 SPRING 19 If necessary remove the output shaft and the low gear assembly from the auxiliary cover See the following procedure c Remove the collar from the low synchronizer Figure 16 14 a Support the auxiliary cover on the low gear in a press Make sure the output shaft is toward the top of the Figure 16714 press Figure 16 16 COLLAR b Puta sleeve on the top of the output shaft Press the output shaft from the low gear assembly and the cover Figure 16 16 Figure 16 16 OW SYNCHRONIZER 18 If worn or damaged remove the front and rear bearing cones from the upper and lower auxiliary countershafts Use a puller to remove the cones from the countershaft Make sure the jaws of the puller are under the bearing races Figure 16 15 Page 160 Nine Speed and Ten Speed Section 16 Transmissions Overhauling the Auxiliary Case c Remove the outer bearing cone 20 If necessary remove the inner and the and the spacer from the cover outer bearing cups for the output shaft Figure 16 17 from the auxiliary cover See the following procedure Figure 16 19 Figure 16 17 a Support the case on a press Make OUTER sure the inner surface of the case Is BEARING toward the top of the press CONE b Puta sleeve on the outer
155. n the cover plates to the countershafts and the cover Section 11 Removing and Installing the Auxiliary Case NOTE Holding Cover Plate templates are found in Section 20 Specifications Holding Cover Plates can be made from the pattern shown in Figure 11 23 Figure 11 22 HOLDING COVER PLATE 3305 W 1141 Figure 11 23 4 5 0 11INCH ___ 114 30 3 00 mm A 1 25 INCH 1 INCH 32 00 mm 41 15 mm 0 437 INCH 11 11 MM DIAMETER 0 25 INCH 3t 6 35 MM Page 95 Section 11 Removing and Installing the Thirteen Speed Auxiliary Case Transmissions AX CAUTION If required remove the dowel pins from the case side Do not hit the ends of the dowel pins If the ends of the dowel pins are damaged the auxiliary case will be difficult to separate from the main case Also the lower dowel pin cannot be removed from the yoke side of the auxiliary case 7 Clean the dowels pins Remove paint rust and dirt from the pins so that the auxiliary case can be removed Lubri cate the dowel pins with new oil that is used in the transmission Make sure the dowel pins are not damaged Replace damaged dowel pins after the auxiliary case Is re moved 8 Remove the mounting capscrews and washers from the auxiliary case 9 Clean the puller holes in the auxiliary case Install a 3 8 16 x 1 1 2 UNC capscrew into the three puller holes Evenly tighten each capscrew to separate the auxiliary
156. n the output shaft is rotated if the dial indicator and the Countershaft End Play Checking Tool are correctly in stalled If runout occurs make sure the tip of the dial indicator and the align ment mark on the shaft plug are aligned 7 Install a dial indicator so that the tip of the indicator is in the center of the shaft plug Make sure the tip of the dial indicator is also aligned with the alignment mark on the shaft plug Figure 18 5 8 Install a torque wrench in the end of the actuator arm The torque wrench must be installed in a straight line with the actuator arm Figure 18 5 Figure 18 5 JY Page 202 9 Measure the auxiliary countershaft end play See the following procedure 4 caution Apply the force on the torque wrench until after the end play is checked If the force is released the procedure must be repeated a Use the torque wrench to apply a force of 25 lb ft or Ib in 34 N m in one direction Figure 18 6 Figure 18 6 CLOCKWISE ROTATION y NZ UV JH Soff 8 Qo DIRECTION OF FORCE b Put reference marks on the output shaft and the auxiliary case When the output shaft is rotated in this procedure the starting and stop ping positions of rotation must be in the same location c Rotate the output shaft at least four 4 complete turns in a clockwise direction Make sure the starting and stopping positions of rotation are at the s
157. n the piston housing cover Figure 3 7 Put the filter and regulator assembly on the top of the range cylinder Install the mounting capscrews and washers Tighten the capscrews to 85 115 Ib in 10 12 N m Connect the RED air line to the DELIV ERY port on the filter and regulator assembly Connect the air line from the air supply system to the SUPPLY port on the slave valve stamped letter S on the valve Figure 3 9 Operate the vehicle Check the air shift system for correct operation Section 3 In Vehicle Service Figure 3 9 FILTER AND REGULATOR ASSEMBLY Be sum SOY TA ME A Removing the Output Yoke and the Oil Seal NOTE Before replacing the oil seal make sure of the following 1 The oil seal leaks The lip of the oil seal is packed with grease Under normal conditions the area between the lip of the oil seal and the yoke is wet To check if the seal leaks clean the area around the seal Make sure the oil is at the specified level If drops of oil appear the seal must be replaced If the area between the lip of the seal and the yoke is wet do not replace the oil seal 2 The correct oil is in the transmis sion If the wrong oil is used the oil seal will be damaged and leak See Transmission Oil Specifications in Section 20 3 The yoke is not worn or damaged If the yoke is worn or damaged re place the yoke Do not repair yokes Page 29 Secti
158. nch 0 444 mm shim One 0 0325 inch 0 825 mm shim The total shim pack thickness is 0 075 inch 1 903 mm C Install shim KIT 5364 in the bore for the front countershaft bearing Make sure the slots for the oil passage on the shims are aligned with the oil passage hole Install the retainer for the front countershaft bearings Install the Allen head capscrews Alternately and evenly tighten the capscrews to 120 140 Ib in 14 16 N m T Check the end play as described in steps 1 5 of this procedure Find the end play measurement determined in step 5 of this proce dure in the Main Countershaft End Play Chart for Shim KIT 5364 in Figure 17 9 Remove shims to get the specified end play of 0 002 0 006 inch 0 050 0 152 mm Check end play again Make sure the front cup touches the retainer If the reading is 0 002 0 006 inch 0 050 0 152 mm the end play is correct See step 14 Page 197 Section 17 Main Countershaft End Play Adjustment Figure 17 9 Main Countershaft End Play Chart for Shim KIT 5364 REMOVE THESE SHIMS 2803 R 2826 2803 S 2827 2803 W 2831 2803 C 2837 END PLAY MEASUREMENT 0 0050 INCH 0 0075 INCH 0 0175 INCH 0 0325 INCH INCHES MM ORO 127 MM OR0 190 MM OR 0 444 MM OR 0 825 MM 0 002 0 007 0 050 0 177 me __00080010 0 178 0 254 1 e 0 011 0 012_ 0 255 0 304 1 c0 0 013 0 015 03050381 2 c 001600017
159. nizer springs or pins Damaged synchronizer Bent or broken shift shaft in range cylinder Bent or broken shift fork in range cylinder Dirt between splines and gears Missing HI LO fork pin and nut 1 Tighten air lines and fittings Change routing or replace air lines Replace filter regulator assembly if pressure at delivery port is not within 60 65 psi Replace O ring on piston Tighten or replace nut Replace sliding clutch Replace shift fork Replace collar on range shift fork Tighten or replace air lines or fittings Change routing or replace air lines Replace filter regulator assembly if pressure at delivery port is not 60 65 psi Replace slave valve Replace slave valve Replace O rings and or piston in piston housing Replace pin Replace shift knob selector valve Replace disc in slave valve Replace output shaft Replace synchronizer springs or syncnronizer Replace synchronizer Replace shift shaft Replace shift fork Drain oil Flush inside of housing Fill to specified level with new fluid Replace HI LO fork pin and nut To check leakage at the range cylinder first put the selector valve in the LO range Disconnect the air line to the HI range port on the piston housing Operate the vehicle to charge the air system If air leaks are heard the O ring or the piston must be replaced When the nut is loose or missing
160. ntami nants between the rear bearing cup and the case Repeat steps 6 9 Remove the auxiliary case and check that the front cup for the auxiliary countershaft is correctly installed in the main case Check the cover of the auxiliary counter shaft for damage Make sure the cup is installed correctly Repeat steps 6 9 Page 203 Section 18 Auxiliary Countershaft End Play Adjustment 12 If the reading is 0 007 inch 0 177 mm b Remove the Countershaft End Play or more the end play must be ad Checking Tool justed See the following c Remove the blue spacer washer a Choose the correct spacer washer Part Number 1229 N 4538 that according to the dial indicator was used to check the end play reading in step 9 See the chart in Figure 18 9 to choose the correct spacer washer End Play Spacer Measurement Thickness Washer Inh MM Inch Part Number 0 002 0 006 1229 N 4538 0 007 0 012 1229 P 4540 0 013 0 017 1229 Q 4541 0 018 0 022 1229 R 4542 0 023 0 027 1229 S 4543 0 028 0 032 1229 T 4544 0 033 0 038 1229 U 4545 0 039 0 043 1229 V 4546 1229 W 4547 1229 X 4548 ed ee above above NOTES If the reading is 0 059 inch 1 498 mm or there is no reading check the following Check for dirt or other contaminants between the rear bearing cup and the case Remove the auxiliary case and check that the front cup for the auxiliary countershaft is correctly installed in the main case Check the cover
161. oles Figure 7 2 5 Remove the mounting capscrews and LOCATION washers from the top cover IF USED d caution Use a rubber mallet or dead blow hammer to separate the top cover from the transmission case Do not use pry bars or screwdrivers to separate the cover from the case Pry bars or screw drivers may damage the cover and case mounting surfaces If the cover is still difficult to remove remove the slave valve and the interlock pin from the main case 6 Remove the top cover from the trans mission case Figure 7 3 7 Use scraper to remove the sealant OKO material from the top cover and the transmission case Page 51 Section 7 Removing and Installing the Top Cover Assembly 4 Make sure the transmission is in the mE the Top Cover NEUTRAL position 5 Use Loctite Master Gasket Sealant 1 Inspect the tips of the forks If the tips of the forks are worn or damaged replace the forks Inspect the shift sleeves Ifthe sleeves are worn or damaged replace the sleeves To replace the fork or the sleeve see Section 8 Overhauling the Top Cover 2 Inspect the set screws if the set screws are loose see the following a Clean the threads of the set screws Make sure all dirt is re moved from the threads NOTE See the specifications of the sealant manufacturer for the cure time b Apply Loctite 242 Meritor Part Number 2297 V 5430
162. ollers and on the parts Figure 1 14 surfaces of the cup and cone inner race that touch the rollers Figure 1 14 Figure 1 16 5 Bright wear marks on the outer surface of the roller cage Figure 1 16 Figure 1 16 7 Spalling or flaking on the cup and cone inner race surfaces that touch the rollers Figure 1 17 Page 16 Section 1 General Information Figure 1 17 Figure 1 18 NO SPALLS 2 Replace cups with small spalling or flaking marks or light bruising Figure 1 19 Figure 1 19 Tapered Roller Bearing Cups NOTE The bearing cup and the bearing cone must be replaced as an assembly ex cept when the cup is loose in the bore If the cup is loose in the bore install an oversize cup In all other situations do BRUISES not replace the cup or the cone sepa rately Replace the cup and the cone in a matched set from the same manufac 3 Replace arge spalls turer For replacement part numbers deep indentations Figure 1 20 see the chart in Figure 1 12 1 Normal cup wear is shown as an even wear across the surface of the cup Small indentations are accept able Figure 1 18 Page 17 Section 1 General Information Figure 1 20 LARGE SPALL Ball Bearings Inspect ball bearings for wear and dam age Make sure the bearings rotate in the race Make sure the outer race is not worn or damaged On bearings with grooves make sure the grooves are not worn or damaged Rep
163. om the of the input bearing main drive gear Remove the snap ring from the groove inside the b Use a press and a sleeve to re main drive gear move the input shaft from the bearing Figure 12 26 e lf worn or damaged use a puller tool to remove the bushing from c Remove the spacer from the top of inside the input shaft the gear f Inspect all parts See Inspecting the Parts in Section 1 Page 112 Section 12 Overhauling the Main Case Removing the Main Countershafts 1 Remove the auxiliary drive gear and mainshaft as described in this section See Removing the Mainshaft Figure 12 27 Ce 5 n 2 Remove the input shaft and the main drive as described in this section See Removing the Input Shaft po d um p sd a ait NY 3 If installed remove the long capscrews or the T Handle Tools 3256 Y 1013 from the countershafts 4 Push the countershaft assemblies to the rear of the case Tilt the front of the countershaft up and remove the countershaft Remove the upper and lower countershafts from the case Mark the countershafts for correct installation Figure 12 27 Page 113 Section 12 Overhauling the Main Case Removing the Reverse Figure 12 28 Idler Gear Assembly 1 Remove the upper reverse idler gear assembly and the mainshaft as de scribed in Removing the Mainshaft in
164. om the cover and the retainer Figure 16 6 8 Inspect the oil seal in the output bear ing retainer If the seal is worn or damaged remove and replace the seal Figure 16 6 Figure 16 5 10 O RING RANGE CYLINDER HOUSING OUTPUT BEARING RETAINER Remove the plugs from the output bearing retainer Inspect the O rings on the plugs Replace worn or dam aged O rings If a mechanical speedometer is used inspect the speedometer bushing inside the output bearing retainer If worn or damaged remove the bush ing Hemove the capscrews and the wash ers that fasten the holding cover tools on the auxiliary countershafts Re move the holding cover tools Page 157 Section 16 Nine Speed and Ten Speed Overhauling the Auxiliary Case Transmissions 11 On Design Level 1 Nine Speed Figure 16 8 Transmissions remove the snap ring that fastens the upper and lower coun tershafts in the cover Remove the rear bearing cups Mark the snap rings and cups for the correct location Figure 16 7 Figure 16 7 SPACER WASHER NOTE If a pin and a clip is used to fasten the HI LO fork to the shift shaft replace With a nut and shoulder bolt during assembly 12 Remove the shoulder bolt and the nut or pin and clip that fastens the HI LO fork to the shift shaft Figure 16 9 On Design Level 2 Nine Speed and Ten Speed Transmissions remove the spacers for the upper and lower countershafts Remove the
165. on not replace the cup or the cone sepa rately Replace the cup and the cone in a matched set from the same manufac turer For replacement part numbers see the chart in Figure 1 12 Inspect the cup the cone the rollers and the cage of all tapered roller bearings If any of the following conditions exist the cup and the cone must be replaced 1 The outer surface of the large diameter end of the rollers is worn level with or below the center Figure 1 13 2 The radius at the large diameter end of the rollers is worn to a sharp edge Figure 1 13 Figure 1 12 Tapered Roller Bearing Cup and Cone Replacement Chart Bearing Component Main Countershaft Cup and Cone Design Location Transmission Level Part Number Front All A 1228 W 1349 A 1228 T 1346 1228 Rear A A 1228 V 1348 1228 5 1345 Auxiliary Countershaft Front NOTES Use Part Number XCD2139DT Use Part Number XC11807DN Use Part Number XC1837DF 13 Speed 13 Speed 9 and 10 Speed A 1228 X 1350 3 and 10 Speed A 1228 Y 1351 A 1228 U 1347 Page 15 Section 1 General Information 4 Deep cracks or breaks in the surface of the cup cone inner race or roller Figure 1 15 Figure 1 13 RECESS CENTER Figure 1 15 3 A visible roller groove is worn in the inner race surfaces of the cup or the cone The groove can be seen at the small or large diameter end of both 6 Etching or pitting on r
166. on 3 In Vehicle Service 4 Use the correct tool and the correct procedure to install the seal Use Seal Driver Tool Meritor Part Num ber 3256 Z 1014 or Kent Moore Part Number J 39161 to install the seal Do not remove the output bearing retainer to install the seal If the correct tool and or the correct pro cedure is not used the seal will leak db WARNING Do not work under a vehicle supported only by jacks Jacks can slip or fall over and cause serious personal injury Support the vehicle with safety stands Block the wheels to prevent the vehicle from moving 1 Put the transmission in NEUTRAL Make sure the parking brake is applied 2 Disconnect the driveshaft from the output yoke of the transmission 3 Put a holding tool such as Kent Moore Tool J 3453 Flange Yoke Holding Bar or equivalent on the yoke 4 Put a 2 3 4 inch socket on the nut that fastens the yoke to the output shaft Hemove and discard the nut Figure 3 10 YOKE HOLDING TOOL Page 30 5 Remove the yoke from the output shaft Remove the speedometer tone ring or drive gear from the yoke Re place the yoke if worn or damaged 6 Use a slide hammer and puller such as Snap On Light Duty Puller Set CG2400B or equivalent to remove the seal from the retainer Discard the seal Figure 3 11 Figure 3 11 amp PE S OIL SEAL PULLER FZ GZ Installing the Oil Seal and the Output Yoke 1
167. on 5 Overhauling the Shift Lever and Tower Assembly Figure 5 11 9 If removed connect the upper shift b If clips are used install a bushing in lever assembly to the lower lever See each side Install a clip on one end the following Figure 5 12 of the pin Install the pin in the bores Install the clip on the other a Install the upper shift lever assem end of the pin bly on the lower lever Make sure the bores for the retainers are c lf a bolt and nut is used install the aligned bolt in the bores Install and tighten the nut to 8 12 lb ft 11 16 N m 45 Section 5 Overhauling the Shift Lever and Tower Assembly Figure 5 13 A WARNING To prevent serious eye injury al ways wear safe eye protection when doing maintenance or service Disassembling the SNAP RING Cast Iron Shift Lever and SPRING Tower Assembly SPACER See Figure 5 13 1 Remove the shift lever and tower assembly as described in Section 3 In Vehicle Service 2 If necessary separate the upper shift lever from the lower shift lever See the following a If clips are used remove one clip Remove the clip and pin assembly from the lever Remove the bush ings Figure 5 14 b If a bolt and nut is used remove the nut and the bolt Figure 5 14 Sa HOUSING c Remove the upper shift lever from endi the lower shift lever 3 Remove the clamps that fasten the boot to the housing
168. one from the output shaft and OD gear assembly See the following a Remove the spacer from the shaft Figure 16 71 b Support the assembly in the press by the gear Make sure the threads are toward the top of the press c Puta sleeve on top of the output shaft Press the shaft out of the cone and gear Discard the cone Figure 16 72 25 Remove the spacer from the output shaft Figure 16 73 26 Inspect all parts See Inspecting the Parts in Section 1 Section 16 Overhauling the Auxiliary Case Figure 16 71 SPACER Figure 16 72 Figure 16 73 ULM i j SPACER 181 Section 16 13 Speed Overhauling the Auxiliary Case Transmission Assembling the Auxiliary Figure 16 75 Case Thirteen Speed Transmissions See Figure 16 49 1 Lubricate all the parts of the auxiliary SPACER cover with new oil used in the trans o mission 2 Put timing marks on the OD gear Mark one tooth with paint Mark a second tooth opposite 180 the first timing mark Figure 16 74 5 Install the auxiliary OD gear on the output shaft Figure 16 76 Figure 16 76 TIMING MARKS 3 Put the output shaft on the work bench Make sure the splined end of the shaft is up 4 Install the spacer on the output shaft 6 Install the bearing cone on the output Make sure the small shoulder of the shaft and OD gear assembly See the spacer is towa
169. one in a matched set from the same manufac turer 1 Lubricate all parts with new oil that is used in the transmission 2 Use paint to put a timing mark on two teeth of each countershaft driven gear Make sure the timing mark is aligned 4 with the slot for the key and the O stamping on the countershaft Figure 12 53 Figure 12 53 TIMING MARK COUNTERSHAFT DRIVEN GEAR MARK TWO TEETH OVER THE SLOT FOR THE KEY OR THE O STAMPING 3 Use paint to put a timing mark on one tooth of the main drive gear on the 5 input shaft Put another paint mark directly opposite 180 the first mark Figure 12 54 ON EACH SIDE 180 APART TIMING AGIS VRAA MARKS A A i Install the lower countershaft so that the large gears are toward the front of the case Move the countershaft toward the side of the case Figure 12 55 Figure 12 55 h Install the upper countershaft assem bly in the case The large gears must be toward the front of the case Move the countershaft toward the side of the case Figure 12 56 Page 123 Section 12 Overhauling the Main Case Install a long capscrew or T Handle 6 Rotate the input shaft and move the Tool 3256 Y 1013 in the hole in the lower countershaft assembly so that front of the upper countershaft The the timing marks are aligned tool or the capscrew makes the coun Figure 12 57 terenethedsle
170. onnect the speedometer connec tions from the output bearing retainer 9 If used remove the spring from the clutch lever on the transmission Mark and disconnect the clutch linkage from the clutch housing on the transmission 10 If a hydraulic system is used on the clutch disconnect the push rod and the spring from the release fork Re move the hydraulic cylinder from the bracket on the transmission Use wires to support the cylinder on the frame A WARNING Make sure the transmission is securely supported on the overhead hoist or the jack If the transmission is not securely supported the transmission may fall and cause serious personal injury or damage 11 Support the transmission with an over head hoist or with a transmission jack Make sure the transmission is securely supported 12 Remove the fasteners that attach the transmission to the brackets on the frame Section 4 Removing and Installating the Transmission cauTION Figure 4 3 Make sure the transmission does not i CLUTCH hang by the input shaft The clutch ah assembly and the pilot bearing will be damaged if the transmission is sup ported by the input shaft 10 Remove the bolts and the washers that attach the clutch housing to the en gine Pull the transmission straight out from the flywheel housing Remove the transmission from the vehicle Figure 4 2 11 If used remove the clutch brake as sembly from the input shaft of the transmission
171. or 3 Use an air gun to apply air pressure to the LO range port in the piston housing to put the auxiliary case into the LO range If necessary rotate the output shaft while applying air pressure Figure 11 2 Page 85 Section 11 Removing and Installing the Auxiliary Case 5 Remove the mounting capscrews and washers from the covers of the auxil lary countershafts Remove the cov ers Use a scraper to remove the gasket material on the cover and the case CAUTION Install holding cover plates or lift brack ets on each auxiliary countershaft If not used the countershafts will fall when the auxiliary cover is removed 6 Install Holding Cover Plates 3305 W 1141 on each counter shaft See the following Figures 11 3 and 11 4 a Put the Holding Cover Plate in position on the cover over the countershaft NOTE One or two holes for the holding cover plate may be in the top of the counter shaft b Rotate the output shaft so that the holes in the countershaft are aligned with the holes in the holding cover plate c Use capscrews to fasten the cover plates to the countershafts NOTE Holding cover plate templates are found in Section 20 Specifications The pat tern for the cover plate is shown in Figure 11 4 Page 86 Nine Speed and Ten Speed Transmissions Figure 11 3 d HOLDING COVER PLATE 3305 W 1141 0 11 INCH 4 114 30 3 00 mm 0 50 INCH 12 70 mm 1 25 INCH
172. or equivalent to the threads of the 5699 Meritor Part Number 2297 7021 and a sealant dispenser to put a new 1 8 inch 2 mm sealant pattern for the top cover on the case See Gasket Sealant in Section 1 Figure 7 4 Figure 7 4 FOUR HOLES SURROUNDED BY SEALANT TRANSMISSION CASE capscrews NOTE c Tighten the capscrews to the If the top cover is difficult to install torque in the Torque Specifications remove the slave valve and the inter Chart lock pin from the main case 6 Install the top cover Make sure the cover is in the NEUTRAL position Make sure the forks of the cover a Install the new lockwire engage the collars in the transmission case Figure 7 5 3 Inspect the lockwire If the lockwire is missing or damaged see the following b Bend the wire towards the capscrew c Twist the wire at least once between the parts On the 1 2 sleeve and fork assembly the wire can be wrapped around the shaft Page 52 Section 7 Removing and Installating the Top Cover Assembly Figure 7 5 7 Install the mounting capscrews and washers for the top cover Tighten the capscrews to 25 35 lb ft 34 47 N m 8 Install a detent ball in each of the three holes in the top cover Figure 7 6 NOTE Replace the detent springs as a set Use the yellow spring Meritor part number 2258 D 1278 in all the holes Figure 7 6 DETENT SPRING HEAVY DUTY SPRING LOCATION
173. or the make a 1 8 inch 2 mm sealant pattern output bearing retainer Tighten the for the output CM retainer Make capscrews to 35 45 lb ft 47 71 N m sure the sealant material does not o cover the oil passage See Figure 16 39 for the sealant pattern see Installing the Sealant in Section 1 21 If removed install the oil seal in the output bearing retainer See the fol lowing procedure Figure 16 41 Figure 16 39 seacant CAUTION PATTERN Hold the seal only on the outer diame O ter Do not touch the inner diameter of the seal Touching contaminates the inner diameter of the seal and causes a leak between the shaft and the seal a Lubricate the outer diameter of the seal Put the oil seal in the cover Make sure the letters on the seal are installed away from the re tainer Page 170 Nine Speed and Ten Speed Section 16 Transmissions Overhauling the Auxiliary Case Figure 16 42 Use the correct tool to install the oil seal If the correct tool is not used the seal will leak b Use seal driver tool 3256 Z 1014 Kent Moore Tool Number J 39161 to drive the seal into the cover The seal is correctly installed when the outer flange of the seal touches the retainer Figure 16 41 NOTE If a pin and a clip was used to fasten the HI LO fork to the shaft replace the pin and the clip with a nut NL 25 1 and shoulder bolt 10 X 1534 24 Align the hole of the shaf
174. ore s for the reverse lamp switch Install the switches or plugs and tighten to 35 50 lb ft 48 67 N m Figure 8 61 Figure 8 61 REVERSE SWITCH BORES LONG PIN Page 77 Section 8 Overhauling the Top Cover Assembly 15 Install the short pin in the bore for the neutral safety switch Install the switch or plug and tighten to 35 50 Ib ft 48 67 N m Figure 8 62 16 Install the breather vent in the top cover Tighten to 15 20 lb ft 21 27 N m Figure 8 62 T Figure 8 62 SHORT PIN Page 78 XK Bar Top Cover NEUTRAL SAFETY SWITCH BORE BREATHER VENT Section 9 Removing and Installing the Input Shaft AX WARNING To prevent serious eye injury always wear safe eye protection when doing maintenance or service Removing the Input Shaft Assembly NOTE The input shaft can be removed without disassembling the transmission 1 Remove the transmission from the vehicle See the procedure in this section ACA UTION Use a rubber mallet or dead blow hammer to separate the top cover from the transmission case Do not use pry bars or screwdrivers to separate the cover from the case Pry bars or screw drivers may damage the cover and case mounting surfaces If the cover is still difficult to remove remove the slave valve and the interlock pin from the main case 2 Remove the capscrews and the washers that fasten the input bearing retainer to the main case Remove the
175. ousing Make sure the slot in the 3 4 shift sleeve is aligned with the slot in the 1 2 sleeve Figure 8 58 c Push the shift shaft through the 3 4 shift sleeve e Put the 3 4 X bar sleeve in the housing Make sure the slot is in the sleeve is aligned over the rocking lever assembly Make sure the bore of the sleeve is aligned with the bore in the housing Figure 8 58 3 4 3 4 Figure 8 58 SHIFTER SLEEVE X BAR SLEEVE Page 76 a Bar Top Cover f Push the shift shaft through the 3 4 bar sleeve g Push the shaft through the assem bly until the holes in the sleeves are aligned with the holes in the shaft caution After the set screws with the Loctite sealant see step 2 are tightened to the specified torque do not loosen or tighten If loosened or tightened the set screws must be removed cleaned and new sealant applied or the set screws may loosen during operation h Install the set screws with the Loctite sealant see step 2 that fastens the sleeves to the shaft Tighten the set screws to 35 45 Ib ft 47 54 N m i Install the lock wire in the holes in the sleeves and the set screws NOTE On R ratio transmissions the bill of material refers to the 3 4 shift fork as the O D Overdrive shift fork and the 3 4 X bar sleeve as the O D shift sleeve 12 Install the 3 4 fork and 3 4 shift fork shaft according to the following procedure a Put the
176. owing Figure 14 16 a Install the washer on the shaft Make sure the chamfered side with the dot is towards you b Slide the washer to the fourth groove above the roll pin c Move the washer so that the teeth of the washer are directly over the splines of the shaft The washer must not slide down the shaft If necessary put a small screw driver in the dot on the washer to move the washer Figure 14 16 Figure 14 16 SELECTIVE THRUST WASHER TEETH DIRECTLY OVER SHAFT SPLINES 28 Check the clearance between the low or the first and the first or second gears See the following procedure a Put two screwdrivers across from each other between the first and low or the second and the first gears Figure 14 17 b Lightly push on the screwdrivers to evenly spread the gears Make sure the gears are parallel Figure 14 17 Section 14 Overhauling the Mainshaft Figure 14 17 USE TWO Hint Y SCREWDRIVERS ie TO SEPARATE me NOTE Do not push on the screwdrivers when the feeler gauges are installed c Put two feeler gauges between the hubs Each feeler gauge must be opposite the other The clearance must be 0 006 0 012 inch 0 152 mm 0 304 mm Figure 14 18 Figure 14 18 quud HN miil JURE RN CLEARANCE BETWEEN GEARS 0 006 0 012 INCH CO 152 0 304 MM Page 145 Section 14 Overhauling the Mainshaft d If the clearance is less than 0 006
177. parts in a hot solution tank or with water steam or alkaline solutions These solutions will cause corrosion of the parts Cleaning the Rough Parts Rough parts can be cleaned with the ground or polished parts Rough parts also can be cleaned in hot solution tanks with a weak alkaline solution Parts must remain in the hot solution tanks until they are completely cleaned and heated Drying the Cleaned Parts must be dried immediately after cleaning Dry parts with clean paper rags or com pressed air Preventing Corrosion and Rust on Cleaned Parts Apply lubricant to cleaned and dried parts that are not damaged and are to be imme diately assembled If parts are to be stored apply a special material that prevents corrosion and rust to all surfaces Store the parts inside special paper or other material that prevents corrosion and rust Page 19 Section 2 Lubrication and Maintenance Transmission Oil Transmission Oil Coolers Specifications Use a transmission oil cooler for any of the following CAUTION e transmission operating tempera Use only the specified type of single ture is always more than 225 F 107 C weight oils Do not use multi viscosity at continuous operation or 275 F oils or EP Extreme Pressure gear oils ee 135 C at intermittent operation Multi viscosity oils and EP gear oils may damage components The use of e The engine has a horsepower rating of multi viscosity o
178. r o MONE 7 Install the mainshaft as described in Figure 12 56 this section ur NM LW M p ond J ril QI 3 d COUNTERSHAFT DRIVEN GEAR TIMING MARK Page 124 Installing the Mainshaft WARNING Wear safe eye protection and make sure the tools are in safe condition If the tools are worn or damaged mushroomed pieces can break and Cause serious personal injury To install the mainshaft the input shaft and the main countershafts must be installed in the case NOTE Apply Loctite 242 Meritor Part Number 2297 V 5430 or equivalent on the threads of the fasteners 1 Lubricate all parts with new oil that is used in the transmission NOTE The rear bearing cone must be installed on the upper countershaft Figure 12 58 2 Move the upper countershaft toward the side of the case Figure 12 58 Install a long capscrew or T Handle Tool 3256 Y 1013 in the hole in the Section 12 Overhauling the Main Case Figure 12 59 M MAIN DRIVE GEAR TIMING MARK COUNTERSHAFT DRIVEN GEAR TIMING MARK front of the upper countershaft The tool or the capscrew makes the coun tershaft easier to move 3 Rotate the input shaft and move the lower countershaft assembly so that the timing marks are aligned Figure 12 59 4 Remove the snap ring to remove the auxiliary drive ge
179. r EP gear oils voids the 399 HP or more Some aerodynamic warranty vehicles with less than 399 HP may require a cooler due to the lack of air Use the specified type of single weight oil which flows over the transmission to when adding or replacing oil Use the dissipate heat correct type of oil for the outside tempera ture Engine oil mineral oil and full syn thetic lubricants are recommended DO NOT MIX OILS see the chart in Figure 2 1 for oil specifi cations LUBRICANT TYPE GRADE SAE OUTSIDE TEMPERATURE Full Synthetic Oil Meritor Specification 0 81 Heavy Duty Engine Oil Above 10 F 12 C A P I CD CE SF or SG Above 10 F 12 C Current API Designations Above 15 F 26 C Acceptable MIL L 2104B C Dor E Mineral Oil with Rust and 90 Above 10 F 12 C Oxidation Inhibitor A P I GL 1 80 Above 15 F 26 C Use only the specified type of single weight oils Do not use multi viscosity oils or EP Extreme Pressure gear oils Multi viscosity oils and EP gear oils may damage components The use of multi viscosity or EP gear oils voids the war ranty Page 20 Scheduled Maintenance Every 10 000 Miles 16 000 km of Vehicle Operation e Check and adjust the oil level in the transmission e Check the condition of the breather vent e Check the torque of the fasteners e Inspect for leaks or damage on the transmission Service as necessary Every 50 0
180. r or replace linkage lighten fasteners of loose mounts to specified torque Replace damaged mounts Replace balls or rails Replace shift fork Replace shift shaft Replace mainshaft Fill to specified level Drain oil Use specified oil Replace temperature gauge Replace interlock ball in top cover Replace gears Install correct gear sets Align timing marks on gears Replace shafts Ifa noise is present along with the overheating condition see the Troubleshooting Noise chart to identify and service the noise Ifthe oil is at the specified level and the specified oil is used but the transmission overheats and the oil smells burnt the transmission must be disassembled and inspecged Ifthe oil does not have a burnt smell and the temperature gauge indicates overheating remove and replace the gauge Page 213 Section 20 Specifications Transmission Oil Capacities Transmission Model Us Pins Liters CRMOS 145B 205 Transmission Model Liters Oil capacities are approximate Fill the transmission to the bottom of the fill plug hole On transmissions equipped with an oil pump and or oil cooler operate the engine with the transmission in NEUTRAL and the clutch engaged for five minutes after the initial fill and check the oil level again Transmission Oil Specifications Lubricant Type Grade SAE Outside Temperature Meritor Specification 0 81 50
181. r tightened the capscrews must be removed cleaned and new sealant applied or the capscrews may loosen during operation When installing lockwire do the following a rim excess wire to a 1 4 inch 6 mm length b Bend the wire towards the capscrew C Twist the wire at least once between parts d On the 1 2 sleeve the wire can be wrapped around the shaft nottighten more than the specified torque or the output bearing may be damaged Page 219 Section 20 Specifications Fastener Torque Locations Thirteen Speed Transmissions TOP VIEW SIDE VIEW 1 2 7 6 N J Q m NAI eaa E in pet OR FRONT VIEW FRONT VIEW WITHOUT CLUTCH HOUSING DESIGN LEVEL 2 WITH CLUTCH HOUSING Page 220 Section 20 Specifications Fastener Torque Locations Thirteen S peed Transmissions Continued REAR VIEW REAR VIEW WITH AUXILIARY COVER ic wma 5 OER WITH ROUND RETAINER B O AG Wo j LN Sey 47 y e SON DOCE Q om 7 7 CN Ou N lt a YW 20 ey Lass 2 d XC Ho O 19 a A 23 21 REAR VIEW TOP COVER WITHOUT AUXILIARY COVER STANDARD X BAR DESIGN LEVEL 2 SHOWN WITH TWO PIECE RETAINER Page 221 Section 20 Specifications Fastener Torque Locations Thirteen Speed Transmissions Continued MAIN CASE MAIN CASE REVERSE IDLER GEAR OIL PUMP SECTION B SECTION A A Page 222 Section 20 Specifications Fastener Torque Cha
182. race of the inner bearing cup c Press the inner and the outer cups from the cover Discard the cups d Remove the cover from the press Remove the auxiliary low gear and the inner bearing cone from the cover Figure 16 18 Figure 16 18 COVER 21 On Design Level 1 Nine Speed Transmissions remove the toothed spacer from the output shaft or from inside the low gear Remove the thrust washer from the top of the gear C o se gr m INNER ow BEARIN 161 Section 16 Nine Speed and Ten Speed Overhauling the Auxiliary Case Transmissions NOTE Figure 16 20 115 and 125 series transmissions use TOOTHED WASHER one spacer on the output shaft 135 DESIGN LEVEL 1 145 155 and 165 series transmissions use two spacers on the output shaft OUTPUT SPACER 22 Remove the spacer s from the top of the output shaft Figure 16 20 23 Inspect all parts See Inspecting the Parts in Section 1 LOW GEAR THRUST WASHER DESIGN LEVEL 1 Page 162 Nine Speed and Ten Speed Overhauling the Auxiliary Case Transmissions Assembling the Auxiliary Case Nine and Ten Speed Transmissions See Figure 16 1 NOTE The bearing cup and the bearing cone must be replaced as an assembly Do not replace the cup or the cone sepa rately Replace the cup and the cone in a matched set from the same manufac turer 1 Lubricate all the
183. ransmission Connect the spring to the release lever Connect the air lines to the transmis sion Connect the electrical connectors to the transmission Connect the driveshaft to the output yoke on the transmission Make sure the alignment marks on the output yoke and the driveshaft that were made during removal are aligned Install and tighten the fasteners ac cording to the specifications and the procedure of the manufacturer of the vehicle 24 Connect the shift lever assembly to the transmission If removed install the shift tower assembly on the transmis sion 25 Lubricate the clutch housing the cross shaft bushings and the release bearing housing See the procedure of the manufacturer of the vehicle 26 Adjust the clutch and or the linkage See the procedure of the manufac turer of the vehicle CAUTION Make sure the inspection cover on the clutch housing is used If an inspection cover is not used dirt and contami nants get into the clutch housing and damage the clutch 2 Install the inspection cover Install and tighten the capscrews Tighten the capscrews to the specified torque of the manufacturer of the vehicle 4 CAUTION Use the specified oil Do not use multi viscosity or EP Extreme Pressure GL 5 gear oils The wrong oil will damage the transmission 28 Clean the area by the fill plug Re move the fill plug from the transmis sion Add the specified oil until the oil leve
184. rd the splined end of the following procedure Figure 16 77 shaft for the output yoke Figure 16 75 a Put the output shaft and OD gear assembly on a press Support the shaft on the bottom of the shaft Make sure the large threads on the shaft are toward the top of the press Page 182 13 Speed Transmission Figure 16 77 b CONE LA OD GEAR Install a bearing cone on the shaft Make sure the letters on the cone assembly are toward the gear Put a sleeve on the cone Press the cone on the shaft until the cone touches the gear Make sure the gear and the bearing cone rotates on the shaft Install the spacer on the shaft Figure 16 78 Figure 16 78 Section 16 Overhauling the Auxiliary Case If removed install the bearing cups for the output shaft in the auxiliary cover See the following procedure a Put the auxiliary cover in a press so that the outside of the cover is toward the top of the press Put the inner bearing cup in the cover Make sure the letters on the cup are toward you Install a sleeve or a bearing installation tool on the race of the bearing Press the inner cup into the cover until the top of the cup is 3 8 inch below the outer surface of the cover Figure 16 79 Figure 16 79 INNER CUP 3 8 INCH FROM COVER OUTER SURFACE d Put the outer cup on top of the inner cup Make sure the letters on the cup are toward you Figure 16 80
185. re 14 13 21 Install the spacer on top of the washer Figure 14 13 Page 143 Section 14 Overhauling the Mainshaft AR 22 Install the first or second gear on the shaft Make sure the splines of the gear engage the teeth on the spacer and the snap ring is against the spacer Figure 14 14 Figure 14 14 FIRST OR x GEAR gt gt mr 23 Install the low or first gear Make sure the snap ring is towards the first or second gear Figure 14 15 24 Install a soacer Make sure the teeth of the spacer engage the splines of the gear Figure 14 15 Page 144 Figure 14 15 AS ir Cmm il Hut T ii w 3b CAUTION Make sure the selective washers do not move when the key is removed If the washers move the gears will fall and the assembly must be disassembled and assembled 25 Remove the key 26 Choose the correct selective thrust washer for the low or first gear See the following If the selective washers are not replaced use the original washers If the selective washers are re placed install the thinnest size of washer For transmissions with serial num bers LB93021753 and below use a 0 216 inch 5 50 mm washer For transmissions with serial num bers LB93021754 and above use a 0 272 inch 6 90 mm washer 27 Install the selective thrust washer for the low or first gear See the foll
186. ricate the O ring for the pistons Figure 16 103 with a silicone lubricant such as Dow Corning 111 Silicone Grease or equivalent Install the O rings on the outer diameter and in the bore of the pistons Figure 16 103 34 Install a new nut and the washer that fasten the pistons on the shafts Tighten the nut to 35 50 Ib ft 48 67 N m Figure 16 104 T Page 191 Section 16 13 Speed Overhauling the Auxiliary Case Transmission Figure 16 104 Figure 16 105 AUXILIARY 7 SE PISTON 7 HAFT HOUSING CUP COVER PA 35 If removed install the shuttle valve 36 Install a new gasket between the Lubricate the O rings on the shuttle pO GESIN in cover valve with a silicone lubricant such as Dow Corning 111 Silicone Grease or 37 Install the capscrews and the washers equivalent the fasten the piston housing cover to the piston housing Tighten the cap Install the shuttle valve Make sure the rod of the valve is toward the piston CMSs Se ON o Install and tighten the fitting 38 Install the cups for the rear bearing Figure 16 104 cones of the auxiliary countershafts Put the cones in the correct bores in the transmission case Figure 16 105 Page 192 Section 17 Main Countershaft End Play Adjustment AX WARNING To prevent serious eye injury always wear safe eye protection when doing maintenance or service Checking and Adjusting the End Play of the Main Countersh
187. rinds on Initial correctly correctly Engagement Clutch out of adjustment Adjust clutch Make sure clutch In Vehicle engages and releases correctly Repair Worn damaged or missing Replace clutch brake Make sure clutch brake clutch engages and releases correctly Clutch and or remote shift Lubricate repair or replace linkage housing linkage binding or unable to move Worn bushings in side of clutch Replace bushings in the clutch housing housing Page 212 Section 19 Troubleshooting Troubleshooting Operating Conditions Cont d Shift Lever Locks or Sticks In Gear In Vehicle Repair Shift Lever Locks or Sticks In Gear Remove and Disassemble Transmission Transmission Overheats In Vehicle Transmission Does Not Operate Remove and Disassemble Transmission NOTES 1 Remote shift linkage out of adjustment Clutch linkage needs adjustment Linkage binding or unable to move Loose or damaged cab and or engine mounts Damaged balls or rails in top cover assembly Bent shift fork in top cover Damaged shift shaft in top cover Damaged mainshaft Incorrect oil level Incorrect oil Damaged temperature gauge Missing or damaged interlock ball in top cover Free running gears are locked Mismatched gear sets Timing marks on gears not aligned Broken shafts Adjust remote shift linkage Adjust clutch linkage Lubricate repai
188. rshafts CONE SPLITTER Figure 16 68 GEAR Make sure the jaws of the puller are ee Aa 3 JU Q Use a puller to remove the front cone Figure 16 67 FRONT CONE auxiliary cover See the following procedure Figure 16 69 a Support the auxiliary cover ina press Make sure the output shaft is toward the top of the press b Puta sleeve on the top of the output shaft Press the output shaft and OD gear assembly from the Remove the rear cone and splitter gear SOVER as an assembly Support the splitter c Remove the outer bearing cone gear in a press so that the rear cone is from the cover toward the top of the press Puta sleeve on the countershaft Press the d Remove the cover from the press countershaft from the cone and gear Remove the key from the countershaft Figure 16 69 Figure 16 68 22 If necessary remove the output shaft OUTPUT and the OD gear assembly from the Page 180 13 Speed Transmission 23 If necessary remove the inner and the outer bearing cups for the output shaft from the auxiliary cover See the following procedure Figure 16 70 a Support the case on a press Make sure the inner surface of the case Is toward the top of the press b Puta sleeve on the outer race of the outer bearing cup Press the inner and the outer cups from the cover Discard the cups 24 If worn or damaged remove the inner bearing c
189. rt Thirteen Speed Transmission Item Description Lb Ft 4 Breather Vent 0 3 818NPT 15 20 2127 _ EX Slave Valve to Main Case Capscrew 1 4 20 UNC x 1 1 2 10 12 __8_ Inspection Cover to Clutch Housing Capscrew_ 3 8 16 UNC 5 8 25 35 34 47 9 Coverto Case Capscrew 8 Hole 7 16 14 UNC 3 4 35 45 47 61 12 Clutch Housing to Main Case 1 2 13 UNC x 1 1 2 Capscrew 1 2 13 UNC x 3 1 2 65 85 89 115 Capscrew 14 Front Cup Retainer to Main Case 120 140 Allen head Capscrew in Ibs Capscrew Piston Housing to Auxiliary Case Capscrew 3 8 16 UNC x 3 35 45 47 61 BEEN 7o en o Filter and Regulator to Auxiliary Case Capscrew 1 4 20UNC x 3 4 10 12 Auxiliary Cover to Main Case Capscrew 3 8 16 UNC x 1 1 2 35 45 47 61 20 Output Bearing Retainer to Main Case 3 8 16 UNC x 3 35 45 47 61 Capscrew Yoke to Output Shaft Nut G 2 16 UN 450 500 610 677 PTO Cover to Case Capscrew 6 Hole 3 8 16 UNC x 3 4 35 45 47 61 Capscrew Main Case Capscrew i Cover Housing Nut Capscrew Q Shift Fork to Shift Rail Set Screw 7 16 20 UNF 35 45 47 61 Reverse Idler Gear to Shaft Nut 5 8 18 UNF 75 100 101 135 Oil Pump to Main Case Capscrew G 1 4 20 UNC x 1 1 2 10 13 30 Oil Pump Pick up Tube Bracket to 3 8 16 UNC x 1 2 5 10 7 13 Transmission Case Capscrew See NOTES on the following page Page 223 Section 20 Specifications Fastener
190. s the hub of the li DERE first gear Figure 15 8 E THIRD OR OVERDRIVE GEAR Figure 15 8 7 Put the PTO gear on the press so that the chamfered side of the teeth are toward from the top of the press Put the shaft in the gear Make sure the slot in the gear is aligned with the key mm in the shaft Press the PTO gear on the ont ud OR shaft until the PTO hub touches the inen hub of the third or overdrive gear 8 Put the main drive gear on a press so that the large hub of the gear is toward the PTO gear Put the shaft in the gear Make sure the slot in the gear is aligned with the key in the shaft Put a sleeve on the top of the shaft Press the shaft into the gear until the hub of the main drive gear touches the hub of the PTO gear Figure 15 10 Page 153 Section 15 Overhauling the Main Countershafts Figure 15 10 AX CAUTION Use the bearing inner race for installa tion If pressure is applied to the bear ing cage the bearing will be damaged 9 Install the front and rear countershaft bearing cones in one of the following ways Use a sleeve or a bearing installa tion tool to install the cones Make Page 154 sure the bottom of the cone touches the shoulder on the shaft Figure 15 11 WARNING Follow the instructions of the manufac turer of the bearing heater The heated cones can burn you Use a bearing heater to install the cones on the shaft Make sure the bottom of the cone touc
191. scribed in race of the input bearing step 4 Figure 12 19 Design Level 2 Transmissions b Use a rubber mallet to drive the input shaft the bearing assembly and the main drive gear from the case Figure 12 20 a Remove the snap ring that retains the input shaft in the bearing Figure 12 21 Page 110 Section 12 Overhauling the Main Case Figure 12 23 Figure 12 21 SNAP RING in Q lt d Remove the main drive gear and the spacer from the case b Remove the input shaft from the case If necessary use a rubber Figure 12 24 mallet to drive the input shaft from the case Figure 12 22 Figure 12 24 CT i n CESS 0 0 Figure 12 22 Ml HH UT HH Wj Ul M M E Sf et x ae SS a al ll 4 On Design Level 1 Transmissions if required disassemble the input shaft See the following procedure Figure 12 25 c Remove the input bearing from the case If necessary remove the snap ring from the bearing Figure 12 23 Page 111 Section 12 Overhauling the Main Case Figure 12 25 Figure 12 26 SNAP RING td BEARING SNAP SPACER RING MAIN DRIVE GEAR INPUT SHAFT BUSHING a Remove the snap ring from the side d Remove the Input shaft fr
192. shaft assembly weighs more than 50 pounds Use a lifting device to install the mainshaft into the case to avoid serious personal injury b Putarope or a lifting hook under the first second collar Slide the mainshaft assembly to the rear of the case Figure 12 16 Section 12 Overhauling the Main Case LU Ii iE zi TI 1 zm 11 Ilf HIN MNN Mil end Hum _ s i FLELHI A u ELO TE TR PO i UJ Lb RN ut a CAUTION Hold the reverse gear when removing the mainshaft If not secured the gear can fall from the shaft c Tilt the front of the mainshaft up and lift the mainshaft assembly from the case Figure 12 17 Page 109 Section 12 Overhauling the Main Case Removing the Input Shaft Figure 12 19 The top cover the mainshaft and the auxiliary drive gear must be removed to remove the input shaft 1 Remove the mounting capscrews and washers from the input bearing re tainer Remove the retainer Figure 12 18 Figure 12 18 INPUT BEARING RETAINER 2 Use a scraper to remove the sealant material from the transmission case and the input bearing retainer 3 Remove the input shaft See the correct procedure Design Level 1 Transmissions c lf necessary disassemble the input a Remove the snap ring on the outer shaft assembly as de
193. shaft is visible 4 Install a new snap ring that fastens the auxiliary drive gear on the mainshaft Figure 13 8 5 Install the auxiliary case See Section 11 Removing and Installing the Auxil lary Case Section 14 Overhauling the Mainshaft Disassembling the Mainshaft See Figure 14 1 Figure 14 1 SECOND GEAR THIRD GEAR 6 OR T WASHER OR WASHER OVERDRIVE GEAR THIRD GEAR DODO SPACER OR FOURTH GEAR l SNAP THRUST T WASHER AG SLIDING SPACER COLLAR 7 LOW FIRST GEAR 6 9 pem OR SPACER FIRST GEAR FIRST GEAR 9990 90 THRUST WASHER THRUST SEGOND GEAR SNAP WASHER SLIDING COLLAR Kz E 43 B 9 SPACER I WW N n rj MAINSHAFT g DET SNAP REVERSE ROLL RING GEAR RING SPACER as THRUST i WASHER eX zi ET APPLICATIONS 9 SPEED DIRECT DRIVE TRANSMISSIONS 9 SPEED RATIO OVERDRIVE TRANSMISSIONS 9 SPEED A RATIO OVERDRIVE TRANSMISSIONS 10 SPEED OVERDRIVE TRANSMISSIONS 9 SPEED B RATIO OVERDRIVE TRANSMISSIONS 13 SPEED TRANSMISSIONS 10 SPEED DIRECT DRIVE TRANSMISSIONS Page 137 Section 14 Overhauling the Mainshaft AX WARNING To prevent serious eye injury always wear safe eye protection when doing maintenance or service NOTE The thrust washer on the mainshaft the snap ring in the reverse gear and the front sliding collar are removed when the mains
194. sition Top Cover Assembly 54 Assembling the Standard and Forward Position Top Cover Assembly 60 Disassembling the Standard and Forward Position X Bar T p C v r ASSemMDIy RPM ERE TCU P 66 Assembling the Standard and Forward Position X Top Cover Assembly 72 Section 9 Removing and Installing the Input Shaft 79 PS OVC NE MOU NA 79 Ste Ai the DET STIS D 81 Section 10 Removing and Installing the Clutch Housing 83 Removing the Clutch Housing nennen nennen nennt nnns 83 HOUSING RE E TO 83 Section 11 Removing and Installing the Auxiliary Case 85 Removing the Auxiliary Case Nine Speed and Ten Speed Transmissions 85 Installing the Auxiliary Case Nine Speed and Ten Speed Transmissions 90 Removing the Auxiliary Case Thirteen Speed Transmissions 94 Installing the Auxiliary Case Thirteen Speed Transmissions 98 Removing the Auxiliary Drive Gear 102 Installing the Auxiliary Drive 103 Section 12 Overhauling the Main Case 104 FRE
195. t a lifting bracket to the auxil 5 If the dowels have been removed use jary case a steel drift and a hammer to install the EE dowels Install the dowels from the If a transmission jack is used remove back of the main case flange Install the bottom two capscrews from the the dowels until the end of the dowels output bearing retainer Use cap are 2 5 inches 64 mm from the screws to connect a bracket for the flange Figure 11 32 jack to the retainer Figure 11 33 Page 99 Section 11 Removing and Installing the Thirteen Speed Auxiliary Case Transmissions Figure 11 33 NOTE The auxiliary section must be in the LO range to install the auxiliary case 9 Install the auxiliary case Make sure the dowels holes in the auxiliary case are aligned with the dowels in the main case and that the auxiliary case is evenly installed on the dowels Rotate the input shaft so that the teeth on the auxiliary drive gear align with the teeth on the countershaft driven gears Figure 11 35 BOTTOM TWO CAPSCREWS Figure 11 35 If an overhead hoist is used connect brackets to the bores for the transmis sion case capscrews Figure 11 34 Figure 11 34 10 Remove the lifting bracket s and the lifting device from the auxiliary case 11 Install the auxiliary case against the transmission case If necessary use a rubber or plastic mallet to tap the auxiliary case against the main case 8 Connect a lifting
196. t cone on the counter shaft so that the bottom of the cone is toward the gear Put a sleeve on the inner race of the cone Press the cone on the countershaft The cone is correctly installed when the bottom of the cone touches the gear Figure 16 91 14 Install the auxiliary countershafts in the cover Make sure the timing marks on the OD gears are aligned Make sure the countershaft bearing is completely installed in the cover Figure 16 92 Section 16 Overhauling the Auxiliary Case Figure 16 91 ill Ii TIMING MARKS 15 Install the collar on the output shaft Install the splitter fork and shaft as sembly on the splitter gear assembly Move the fork so that the fork will not touch the splitter gear assembly during installation Figure 16 93 Page 187 Section 16 13 Speed Overhauling the Auxiliary Case Transmission Figure 16 93 Figure 16 94 SPLITTER FORK pr d A AND SHAFT LO GEAR l COLLAR AND HUB ASSEMBLY COUNTERSHAFT TIMING MARKS 16 Install the LO gear and synchronizer assembly on the output shaft inside the auxiliary cover Make sure the high synchronizer is toward you Make sure the timing marks on all the gears are aligned Figure 16 94 NOTE The end play of the auxiliary counter shaft is checked when the auxiliary cover is installed on the transmission 17 On Design Level 1 Transmissions install the cups on the cones of the auxiliary countershafts Instal
197. t with the hole of the shift fork Install the bolt and the lock nut Tighten the nut to 8 12 Ib ft 11 16 N m Figure 16 43 e 22 Put the HI LO shift fork in position so Figure 16 43 that the fork engage the synchronizer collar Make sure the bore of the fork is aligned with the bore of the range cylinder Make sure the hole in the fork is installed away from the cover Figure 16 42 23 Install the HI LO shift shaft from inside the front of the auxiliary cover Make sure the threads on the end of the shaft are installed first Figure 16 42 Page 171 Section 16 Nine Speed and Ten Speed Overhauling the Auxiliary Case Transmissions CAUTION Figure 16 45 Do not use too much silicone lubricant SEALANT PATTERN on the O rings and the bore of the range cylinder housing If too much lubricant is used the range may shift slowly 25 Lubricate the O rings and the bore of the range cylinder housing with the a silicone lubricant such as Dow Corning 111 Silicone Grease or equivalent Install the O ring in the groove in the bore of the range cylinder housing Figure 16 44 Figure 16 44 O RING GHOUNES 2 Lubricate the O rings for the piston ON with a silicone lubricant such as Dow Corning 111 Silicone Grease or equivalent Install the O rings on the outer diameter and the inner diameter of the piston Figure 16 46 Figure 16 46 26 Use a sealant dispenser and Loctite amp RTV Seal
198. talling 117 Removing 116 Noises 210 OD Overdrive Gear Timing Marks 181 Oil Capacities 214 Oil Coolers 20 Oil Draining 23 Oil Level Adjusting 21 Checking 21 Oil Pump Installing 118 Removing 115 Oil Replacing 23 Oil Seal Installing 30 Removing 29 Oil Specifications 20 214 Operating Conditions 211 Output Shaft Assembling 9 10 Speed 164 Assembling 13 Speed 181 Disassembling 9 10 Speed 161 Disassembling 13 Speed 177 Installing 9 10 Speed 166 Installing 13 Speed 183 Removing 9 10 Speed 160 Removing 13 Speed 176 Output Yoke Installing 30 Removing 29 Piston Installing 9 10 Speed 172 Installing 13 Speed 190 Removing 9 10 Speed 156 Removing 13 Speed 174 Piston Housing Installing 190 191 Removing 174 PTO Covers Installing 117 Removing 116 Range Cylinder Installing 171 172 Removing 156 Repairing Parts 19 Replacing Parts 19 Remote Control Assembly Adjusting 24 Installing 33 Lubricating 24 Removing 33 Remote Shift Housing Adjusting 24 Installing 33 Lubricating 24 Removing 33 Reverse Idler Gear Installing 118 Removing 104 Rust 19 Scheduled Maintenance 21 Seal Installing 30 Removing 29 Sealant Installing 12 Patterns 13 14 Removing 12 Specifications 12 Shift Lever and Tower Assembly Assembly Aluminum 43 Assembly Cast Iron 47 Disassembly Aluminum 41 Disassembly Cast Iron 46 Install
199. the selective snap ring for the front upper countershaft bearings in the case Mark the snap ring for cor rect installation Figure 12 10 Figure 12 10 12 On Design Level 2 Transmissions remove the Allen head screws that fasten the front upper countershaft retainer to the case Remove the retainer and the shims Figure 12 11 Section 12 Overhauling the Main Case Figure 12 11 Figure 12 12 PULLER TOOL J41086 A 3256 W 1037 RETAINER CUP AND CONE AX Use hand tools to rotate the forcing screw of the bearing puller tool If power tools are used the tool will be damaged 13 Remove the front upper countershaft bearing cup and cone Use Bearing Puller Tool Meritor Part Number A 3256 W 1037 or Kent Moore Number J 41086 or equivalent to remove the cup and cone Make sure the correct keys of the tool for transmission design level are installed between the jaws of the puller and the countershaft Figure 12 12 If the cup is removed easily the cup is a loose fit cup Discard and replace with a press fit cup and cone assem bly Make sure the correct parts are NOTE Two types of rear countershaft bearing retainers are used on Design Level 2 transmissions One retainer is used on transmissions with serial numbers Been LB93017865 and below The other 14 On Design Level 1 Transmissions retainer is used on transmissions with remove the selective snap ring for the
200. the slave valve Figure 3 6 a Connect the BLACK 1 8 or 5 32 inch outer diameter air line to the pilot port fitting stamped letter 1 Remove the air from the air supply on the valve system b Connect the RED 1 8 or 5 32 inch 2 Disconnect and mark the air lines on outer diameter air line to the pilot the filter and regulator assembly supply port fitting stamped letters PS on the valve 3 Remove the mounting capscrews and the washers from the filter and regula c Connect the RED 1 4 or 5 16 inch tor assembly Remove the filter and outer diameter air line to the supply regulator assembly fitting stamped letter S 4 On thirteen speed transmissions d Connect the BLACK 1 4 or 5 16 remove the O ring from between the inch outer diameter air line to the filter and regulator assembly and the LO range fitting stamped letter L piston housing cover Figure 3 8 e Connect the BLUE 1 4 or 5 16 inch outer diameter air line to the HI range fitting stamped letter H 8 Operate the vehicle Check the air shift system for correct operation Page 28 Figure 3 8 O RING FILTER AND REGULATOR ur ASSEMBLY PES Installing the Air Filter and Regulator Assembly See Figure 3 7 ja On thirteen speed transmissions lubricate the O ring with a silicon lubricant such as Dow Corning 111 silicone Grease or equivalent Put the O ring for the filter and regulator as sembly in the port i
201. the transmission 2 On Design Level 1 Transmissions install the roll pin in the hole in the groove for the key Figure 15 6 WARNING Wear safe eye protection and make sure the tools are is safe condition If the tools are worn or damaged mush roomed pieces can break and cause serious personal injury 3 Use a punch and a hammer to install the key in the groove On Design Level 1 Transmissions make sure the taper on the end of the key is installed toward the roll pin Figure 15 6 4 Put the first or the second gear on a press so that the hub is toward the bottom of the press Put the shaft in the gear Make sure the slot in the gear is aligned with the key Put a sleeve on the top of the shaft Press the shaft until the first gear touches the gear on the countershaft Figure 15 T Section 15 Overhauling the Main Countershaft Figure 15 7 6 Put the third or the overdrive gearona press so that the hub is away from the top of the press Put the shaft in the gear Make sure the slot in the gear is aligned with the key Put a sleeve on the shaft Press the shaft until the FIRST OR hub of the third gear touches the hub SECOND of the second gear Figure 15 9 Figure 15 9 TIN 5 Put the second or the third gear on a press Put the shaft in the gear Make sure the slot in the gear is aligned with the key Put a sleeve on the shaft Press the shaft until the hub of the ars second gear touche
202. tion 4 Removing and Installing the Transmission 34 Removing Ne FANS NSS OM 34 Installing the Transmission ccccceeccseeeceeeeeeeeeseeeeseeeeneeeeseeeseueeseueesaeeesaeesneeesaeeenens 36 Section 5 Overhauling the Shift Lever and Tower Assembly 41 Disassembling the Aluminum Tower 41 Assembling the Aluminum Tower 43 Disassembling the Cast Iron Tower Assembly 46 Assembling the Cast Iron Tower Assembly 47 Section 6 Remote Control Assembly 48 Disassembling the Remote Control 5 48 Assembling the Remote Control Assembly 49 Section 7 Removing and Installing the Top Cover Assembly 50 Removing the Top Cover Assembly cccccecccccsseceeeeeeeeeceeeeesaeeeeseeueeeseaeseeseeeeesanes 50 Installing the Top Cover Assembly oiuenoemeetonecetiqu xii 52 Section 8 Overhauling the Top Cover Assembly 54 Disassembling the Standard and Forward Po
203. top of the splines on the input shaft to the top of the bearing retainer as shown in Figure 4 6 If the distance is more than 8 72 inches 221 48 mm the input bearing retainer is worn and must be replaced Figure 4 6 IF DIMENSION A IS MORE THAN 8 72 INCHES 221 48 mm REPLACE THE INPUT BEARING RETAINER Figure 4 7 Removing and 6 Inspect the shaft and the release fork Make sure the release fork is straight and the tips of the fork are not worn or damaged Replace forks that are worn or damaged Figure 4 7 CROSS SHAFT MUST ROTATE FREELY DAMAGED Make sure the cross shafts rotate freely in the clutch housing Make sure the shaft does not have any excessive radial side to side movement in the housing Inspect the bushings for the Shaft in the housing Replace bush ings and shafts that are worn or dam aged Inspect the splines on the input shaft Make sure the splines are not worn or damaged Inspect the area of travel for the release bearing for damage Use an emery cloth to remove small scratches from the input shaft Re place input shafts that are worn or damaged Figure 4 8 Inspect the end of the input shaft where the pilot bearing is installed If the end is worn or damaged replace the input shaft and the pilot bearing Figure 4 8 Section 4 Installating the Transmission Figure 4 8 MAKE SURE SPLINES ARE NOT DAMAGED 10 Inspect the clutch brake If the tabs or 11 F
204. ure the timing marks are in the correct locations count the number of gear teeth divide the total teeth number by 2 and put the mark in the correct location 1 Put timing marks on the main drive must be between the two marked teeth on each countershaft drive gear Figure 1 6 All the timing marks must be aligned if the transmission is to operate cor rectly If the timing marks are not painted in the correct position on the gears only one set of marks will be aligned gear on the input shaft Mark one tooth with paint Mark a second tooth opposite 180 the first timing mark Figure 1 5 Use paint to put timing marks on two teeth next to each other on each driven gear of the main countershafts Make sure the marks are aligned with the slot for the key or the stamping on the countershaft Figure 1 5 During assembly each of the two timing marks on the main drive gear Page 10 NOTE The main shaft and the auxiliary drive gear must be installed when the align ment marks in the transmission case are checked 4 To check the alignment of the timing marks rotate the input shaft All the gears must rotate 5 For complete service procedures see Assembling the Transmission Case in Section 12 Overhauling the Main Case Section 1 General Information Figure 1 5 COUNTERSHAFT DRIVEN GEAR MAINDRIVE GEAR MARK TWO TEETH OVER MARK ONE TOOTH THE SLOT FOR THE KEY ON EACH SIDE O
205. ve both drain plugs Drain and discard the oil 2 Disconnect and mark these air tubes Figure 11 21 Figure 11 20 a BLACK tube from the LO range port on the piston housing b BLUE tube from the HI range port on the piston housing cover c RED tube from the supply port of the filter and regulator assembly d Splitter tube on piston housing cover Page 94 Thirteen Speed Transmission 4 On gear driven speedometers remove the driven gear from the out put bearing retainer and the drive gear from the output shaft On electronic speedometers remove the sensor from the output bearing retainer and the rotor from the output shaft or disconnect the sensor at the connector 5 Remove the mounting capscrews and washers from the covers of the auxil iary countershafts Remove the cov ers Use a scraper to remove the gasket material AX CAUTION Install Holding Cover Plates on each auxiliary countershaft If not used the countershafts will fall when the auxil lary case is removed 6 Install Holding Cover Plates 3305 W 1141 on each counter shaft See the following Figure 11 22 a Put the Holding Cover Plate in position on the cover over the countershaft NOTE One or two holes for the holding cover plate may be the top of the counter shaft b Rotate the output shaft so that the holes in the countershaft are aligned with the holes in the Hold ing Cover Plate c Use capscrews to faste
206. vel 1 Transmissions if removed install the snap rings in the bores for the cups for the auxiliary countershafts in the main case Figure 11 11 If removed install the bearing cups for the auxiliary countershaft in the bores in the main case Clean the outer diameter of the cups On Design Level 1 Transmissions make sure the cup is against the snap ring Figure 11 11 On Design Level 2 Transmissions make sure the cup is against the step in the bore Figure 11 12 Page 90 Figure 11 11 Nine Speed and Ten Speed Transmissions AUXILIARY COUNTER SHAFT CUP Nine Speed and Section 11 Ten Speed Removing and Installing Transmissions the Auxiliary Case Figure 11 13 AUXILIARY COVER TO TRANSMISSION CASE GASKET PATTERN e PUT THE PATTERN ON THE TRANSMISSION CASE AND THE AUXILIARY COVER TRANSMISSION CASE GASKET PATTERN AUXILIARY COVER GASKET PATTERN TE TRANSMISSION CASE APPLY SEALANT IN A 1 8 INCH 4 Use a sealant dispenser and Loctite RTV Sealant 5699 Meritor Part Number 2297 A 7021 to put a new sealant pattern for the auxiliary case on the transmission case a 1 8 inch 2 5 INCHES 64 mm 2 mm bead in the pattern shown in Figure 11 13 Put a sealant pattern around each puller hole in the auxiliary case as shown in Figure 13 See Gasket Sealant in Section 1 Figure 11 14 WARNING When using a hammer and a steel drift wear safe eye protection and make sur
207. wer auxiliary countershaft Figure 16 37 Figure 16 37 16 On Design Level 1 Nine Speed Transmissions do the following a Install the snap ring that retains the cups in the case Use the snap ring that was removed during disassembly b install Holding Cover Tools 3305 R 1214 on each countershaft Use capscrews to fasten the cover tools to the countershafts and the cover Figure 16 38 On Design Level 2 Nine Speed and Ten Speed Transmissions do the following a Install the selective washers in front of the cups Make sure the tabs on the washers are in the slots in the case Figure 16 38 b Install Holding Cover Tools 3305 R 1214 on each countershaft Use capscrews to fasten the cover tools to the countershafts and the cover Figure 16 38 Page 169 Section 16 Nine Speed and Ten Speed Overhauling the Auxiliary Case Transmissions Figure 16 38 19 Install the output bearing retainer on the auxiliary cover Make sure the oil passage in the retainer is aligned over the oil hole in the cover Figure 16 40 Figure 16 40 HOLDING COVER TOOLS 3305 R 1214 17 If removed use the correct driver tool to install a new bushing for the speed ometer gear inside the output bearing D TBUT retainer BEARING 18 Use a sealant dispenser and Loctite amp DEAE RTV Sealant 5699 Meritor Part o0 Number 2297 A 7021 equivalent to Install the mounting capscrews t
208. ws Make sure the outside of the housing is toward you NOTE Two or three spring washers may be installed in the housing Make sure the same number of washers are installed 2 Install the spring washers in the bottom of the housing Make sure the large ends of the washers touch and the bevels of the washers are installed away from each other as shown in Figure 5 7 Figure 5 7 Page 43 Section 5 Overhauling the Shift Lever and Tower Assembly 3 Install the lower retainer plate in the housing Make sure the tabs of the retainer are in the slots in the housing 4 Install the lever so that the slots in the lever are installed over the pins Figure 5 8 5 Install the upper retainer plate over the lever and in the housing Make sure the tabs on the plate are installed in the slots in the housing On some housings make sure the pins in the plate are aligned with the slots in the ball on the lever Figure 5 8 Figure 5 8 LEVER SET AS RETAINER 277 PR S 6 Install the snap ring that fastens the upper retainer plate and the lever in 8 Install the boot on the housing Make the housing Figure 5 0 sure the lip on the boot is installed in the groove in the housing Install the clamps or cable ties that fasten the boot to the lower lever and the hous ing Figure 5 11 7 Install and tighten the set screw that fastens the upper retainer plate in the housing Figure 5 10 Page 44 Secti
209. ws with the Loctite amp sealant see step 2 to 10 13 Ib ft 13 17 N m Figure 8 31 16 If removed install the small scoop on the housing Install and tighten the capscrews with the Loctite amp sealant see step 2 to 10 13 Ib ft 13 17 N m Figure 8 31 e Page 65 Section 8 X Bar Overhauling the Top Cover Assembly Top Cover Disassembling the Standard and the Forward Position X Bar Top Cover Assembly See Figures 8 32 and 8 33 Figure 8 32 SPRING REVERSE SWITCH REVERSE PLUG SWITCH BREATHER VENN NEUTRAL SWITCH LUG OIL SCOOP N SHORT o PIN STANDARD Su POSITION HOUSING FOR FORWARD POSITION HOUSING SEE BOX SPACER PLATE ROCKING LEVER GUIDE PIN FORWARD POSITION HOUSING Page 66 Bar Section 8 Top Cover Overhauling the Top Cover Assembly i LL Figure 8 33 Qy __ LOW REVERSE E FORK SPRING 27 1 2 SLEEVE LOW REVERSE SHAFT LOCKWIRE A RN AFT LOCKWIRE INSTALLATION NOTES 1 Trim excess wire to 1 4 inch 6mm 2 Bend the wire towards the capscrew 3 Twist the wire at least once between parts 3 4 FORK 4 On the 1 2 sleeve the wire can be wrapped around the shaft 5 Make sure the wire does not interfere with the movement of the rail A WARNING NEUTRAL To prevent serious eye injury al Poo ways wear safe eye protection when doing maintenance or service NOTE The st
210. y from moving when the high synchronizer is installed e Push down on the high synchro nizer so that the pins of the low synchronizer are installed in the holes in the high synchronizer Figure 16 35 LOW SYNCHRONIZER c Install the springs into the holes in the high synchronizer Use grease to retain the springs Use a multi purpose lubricating grease with NLGI Number 2 rating Figure 16 34 Figure 16 35 d Install the high synchronizer on the pins of the low synchronizer cone Rotate the high synchronizer so that the springs are against the side of the pins of the low synchronizer Figure 16 34 Page 168 Nine Speed and Ten Speed Section 16 Transmissions Overhauling the Auxiliary Case 11 Support the output shaft so that the cover is in the upright position 12 Make sure the timing marks on the low gear and each auxiliary countershaft are in alignment 13 Install the synchronizer assembly on the output shaft inside the auxiliary cover Make sure the high synchro nizer is toward you Figure 16 36 Figure 16 36 AUXILIARY COUNTERSHAFTS i OM NEN SYNCHRONIZER ASSEMBLY yp o OR 22 oh VA e NOTE The cup was marked during disassem bly Make sure the cup is installed in the correct location 14 Install the correct cup on the rear bearing of the upper auxiliary counter shaft Figure 16 37 15 Install the correct cup on the rear bearing of lo

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